Ural (Урал) - Dnepr (Днепр Electric Starters · Ernie Franke [email protected] 09 /...

Ural (Ural (УралУрал) ) -- Dnepr (Dnepr (ДнепрДнепр))Electric Starters Electric Starters

for for Russian MotorcyclesRussian Motorcycles

Part I: Electric StarterPart I: Electric Starter--MotorsMotors(See Also Part II: Hitachi Starter(See Also Part II: Hitachi Starter--Generators, Generators,

Part III: Repair of StarterPart III: Repair of Starter--Motors andMotors andPart IV: Adding a StarterPart IV: Adding a Starter--Motor)Motor)

Ernie FrankeErnie Frankeeafrankeeafranke@@tampabaytampabay..rrrr.com.com

09 / 201309 / 2013

Electric Starter HistoryElectric Starter History•Ural Was Only Kick-Start When Bikes Were Imported to USA in 1994 thru 1997 –CSMI (Classic Motorcycles and Sidecars, Inc) Replaced 14-Amp Russian (Г-424) Generator with 18-Amp Hitachi Starter-Generator on Imported Urals in 1998–See Part II: Hitachi Starter Generator–Did Not Work Well and Discontinued Almost as Soon as Introduced•Starter-Generator on Top of Motor, Working Off the Timing Gear Set•Inadequate Charging and Inadequate Starter

•Ural Added a True Starter-Motor in 1998-1/2–Modified Bell Housing of Gearbox to Accept a Real Starter–Starter Required Larger Battery and 35-Amp Alternator (14.3771)–Used Starter CT369, Originally Developed for Russian Outboard Engine–'98 Models Sold With and Without Starters until Non-Starter Inventory Depleted–35-Amp Alternators (Russian Hand-Grenade) Started Failing, but There Wasn't Any Replacement at that Time•In 2004, 55-Amp Nippon Denso Alternator Replaced 35-Amp Russian Grenade

•Starter-Motor Design Changed to CT369Б Version around 2006–Lengthened by 22 mm (approx. 1”) for 30% Reduction in Current Consumption–Production Bikes Equipped with Proper Kick-Start Levers (1” Kink in Lever)–Problem Only for Older Replacements: Need to Modify Levers•Interference Fit with Kick-Start Lever•F2 (England) and Gene Holopaw Offered Modified Levers

•Schematics of Urals with Starters Included–See Part IV for Hitachi Starter / Generator Schematic

•Dnepr Never Manufactured a Bike with Electric Start, Only Retro-Fit Kits

Ural Starter / Generator / Alternator TimelineUral Starter / Generator / Alternator Timeline

EngineEngineSizeSize

YearYear‘96 ‘07‘04‘02‘98

1998.52000

New Wiring Harness (Electrona in Austria)

650 cc 750 cc Engine

New Engine Design (Alternator on top / Flywheel Starter

placed on bottom)

Gen/Gen/AltAlt

IgnitionIgnitionTypeType

1994 ‘95Ural imported to U.S. by CSMI (Classic

Motorcycles and Sidecars, Inc.)

18-AmpHitachiStarter-

Generator(200-W)

Kick-Start Only

55-Amp Nippon Denso Alternator

(770-W, metal rear cap)

RoughlyWattage = 14 Volts X Amps 35-Amp

Russian Alternator14.3771 (Hand Grenade)

(500 W, black-plastic rear cap) (Longer by 20 mm)14 Amp

Russian-BuiltГ-424 (G-424)

Alternator(150-Watt)

Voltage Regulator internal to Alternator

Factory ElectricFactory Electric--Start AddedStart Added

Type V(Type IV with

electronics moved into airstream)

Ducati

Type IType II Type III Ignition Type IV

Factory ElectricFactory Electric--Start Start (E(E--Start) OfferedStart) Offered

(Starter at Flywheel, (Starter at Flywheel, Alternator on Top Center)Alternator on Top Center)

Electric-Start (E-Start) Option & Retro-fit introduced by CSMI

StartStartRelaysRelays(RY(RY--115)115)

One Relay One RelayTwo Relays

No Points-Ignition UralsApproved for U.S. sale

New Transmission Case(Flywheel Starter Added,

New Wiring Harness)

‘03 ‘05

VoltageVoltageRegulatorRegulator

Regulator Internal to AlternatorPP-330 Mechanical(33.3720200 Solid-State)

‘97 ‘99 ‘01 ‘06

750cc Breakdown Showing Electric Starter Motor750cc Breakdown Showing Electric Starter Motor

The starter-motor is bolted to the gearbox flange and engages the geared flywheel on the engine.

Flywheel with Starter Gear RingFlywheel with Starter Gear RingElectricElectric

StarterStarter--MotorMotor

KickKick--Start LeverStart Lever

GearboxGearbox

PrePre--1998 Ural 650s without Electric1998 Ural 650s without Electric--StartStart

1993 Ural Tourist1993 Ural Tourist

Г-424 Generator

Ural 650 ccUral 650 cc

No ElectricNo Electric--StartStart

Prior to 1998, Urals only had foot kick-start.

PostPost--1998.5 / Pre1998.5 / Pre--2003 Ural 6502003 Ural 650’’s with Electrics with Electric--StartStart

2002 Ural Bavarian Classic2002 Ural Bavarian Classic(650cc)(650cc)

After 1998, Urals only had optional electric-start for their 650’s.

2000 Ural Patrol (650 cc)2000 Ural Patrol (650 cc)2000 Ural Bavarian Classic2000 Ural Bavarian Classic(650cc)(650cc)

2000 Ural Deco (650cc)2000 Ural Deco (650cc)

PostPost--2003 Ural 7502003 Ural 750’’s with Electrics with Electric--StartStart

2000 Ural Retro2000 Ural Retro

2013 Gear2013 Gear--UpUp

2008 Ural Tourist LX2008 Ural Tourist LX 2010 Ural Patrol T2010 Ural Patrol T

With the conversion to 750cc in 2003, electric-start was standard.

Notice Longer StarterNotice Longer Starter--Motor and Motor and the Kickthe Kick--Start Lever with a Start Lever with a ““KinkKink””

Ural StarterUral Starter--Motor Derived from Popular Russian Outboard EngineMotor Derived from Popular Russian Outboard Engine•Outboard Motors "Whirlwind" (Vortex) Popular in USSR

– "Whirlwind-25“ (Вихрь-25) and "Vortex-30" (Вихрь-30): 25 and 30 Hp

The CT369 starter is used in the Whirlwind (Vortex) outboard engines, popular in the USSR and built in Irbit (home-town of Ural).

ELECTROMASH,ELECTROMASH, KhersonKherson Electric Plant, UkraineElectric Plant, Ukraine

1 and 4. Assembly Shop 1 and 4. Assembly Shop 2. Machine shop 2. Machine shop 3. Press Room3. Press Room5. Under Construction5. Under Construction7. Administration7. Administration

•The CT369 (ST-369) Is Manufactured byElectromash in the Ukraine•Company Electromash Founded in 2002–E-mash (Эл-маш)•Only Ukrainian Designer and Manufacturer of Starters and Alternators for Automotive, Tractor and Motorcycle Engines, Motor Vehicle Electric Cooling Fans and Tractor Magnetos

Electric Starting Motor in Electric Starting Motor in ““VortexVortex--30" 30" 14. Electric Starter CT14. Electric Starter CT--369 369 19. 1219. 12--Volt Car Battery Volt Car Battery

Electric Starter Motor for Outboard MotorElectric Starter Motor for Outboard MotorFlywheel with GearFlywheel with Gear

The CT369 starter engages the flywheel of the Vortex 30 Hp outboard engine.

Original Original Electric Starter CT369 (ST369)Electric Starter CT369 (ST369)•Four-Pole DC Motor•Single-Wire Supply with a Return thru Ground or Chassis•Consists of a Body (1), Attached to Pole Field Coils (2), Drive Cover (3),Commutator Cover with Brush Holder (4), Rotor or Armature (Anchor) (5), Ring Collector (Commutator) (6), Drive Gear (7) and Relay Solenoid (8)

1. 1. BodyBody2. 2. Pole with Field CoilsPole with Field Coils3.3. Drive CoverDrive Cover4.4. CommutatorCommutator CoverCover5. 5. Motor Anchor (Rotor or Armature)Motor Anchor (Rotor or Armature)6. 6. Ring Type Collector (Ring Type Collector (CommutatorCommutator))7. 7. Drive GearDrive Gear8.8. Traction RelayTraction Relay9.9. Relay Anchor (Armature)Relay Anchor (Armature)10.10. LeverLever11.11. Rod or StemRod or Stem12.12. Movable ContactMovable Contact13.13. TerminalTerminal14.14. Terminal LugTerminal Lug15.15. Return SpringReturn Spring16.16. Return SpringReturn Spring

The CT369 solenoid pulls the lever (10), which engages the starter drive gear (7) into the motorcycle’s flywheel gear.

Electric Starter, 12Electric Starter, 12--VV(Ural)(Ural)Part #: IMZPart #: IMZ--8.1248.124--1807518075--1010Vendor ID: 003.899Vendor ID: 003.899List Price: List Price: €€180.00180.00(www.(www.oldtimergarageoldtimergarage..eueu))

Ural Electric StarterUral Electric Starter

Inscription: IMZInscription: IMZ--8.1248.124--1807518075--1010

Inscription: 320.3708Inscription: 320.3708

The earliest CT369 was the shorter electric starter for Urals.

On the Earlier Version (CT369),On the Earlier Version (CT369),the Terminals Are Nearly Flushthe Terminals Are Nearly Flush

(10mm) with the End(10mm) with the End--Cap.Cap.

Old Old && New (Longer)New (Longer) CT369 Diagram CT369 Diagram (www.(www.electromashelectromash.com..com.uaua))

The EndThe End--Cap of the Later Version (CT369Cap of the Later Version (CT369ББ) Extends about 25mm ) Extends about 25mm Beyond the Electrical Terminals. On the Earlier Version (CT369),Beyond the Electrical Terminals. On the Earlier Version (CT369),

the Terminals Are Nearly Flush (10mm) with the Endthe Terminals Are Nearly Flush (10mm) with the End--Cap.Cap.

ФФ80mm80mm

157.5157.5mmmm

172.5172.5mmmm

EndEnd--Cap of the Later Version (CT369Cap of the Later Version (CT369ББ) Extends ) Extends about 25mm Beyond the Electrical Terminals. about 25mm Beyond the Electrical Terminals.

The new starter may not have any problem fitting in the Russian outboard motor, but the extra length of the starter interferes with the Ural kick-start lever.

Electric Starter 391.3708 Electric Starter 391.3708 for Russian for Russian VAZVAZ--1111 "OKA" Car 1111 "OKA" Car

(Manufacturer(Manufacturer ElectromeshElectromesh))

11111111--3708800:3708800: Starter Solenoid Starter Solenoid for VAZfor VAZ--1111 Starter1111 Starter

The 391.3708 or 7102.37087102.3708 starter-motor, as seen on the Internet, is used in the Russian VAZVAZ--1111 "OKA" 1111 "OKA" car, and will not fit the mounting holes of the Ural.

Ural ElectricUral Electric--Start Motor Has Various DesignationsStart Motor Has Various Designations•Original “А” Version of CT369–Alternate Transliteration: ST369–Ural Part #: IMZ-8.103-18075 (ИМЗ-8.103-18075) •650/750cc, 2003 -2006 Parts List–Ural Part #: IMZ-8.124-18075-10 (ИМЗ-8.124-18075-10)–Electromash Part #: 320.3708–Electromash Part #: 392.3708•Replacement “B (Б)” Version: CT369Б–Alternate Transliteration: CT369B or ST369Б–Ural Part #: IMZ-8.103-18075 (ИМЗ-8.103-18075) •650/750cc, 2007 -2010 Parts List–Ural Part #: IMZ-8.124-18075 (ИМЗ-8.124-18075) •650/750cc, 2009 and 2011 Parts List–Electromash Part #: 369Б.3708•Possible Russian Starter (Add-On, Requires Modifications)–Use OKA (Ока) Starter for Lada VAZ-1111 (ВАЗ 1111) Car–VAZ-1111: Basic Russian Car with a 2-cylinder, 750cc, 35 Hp Engine•Part #: 391.3708 or 39.3708

Hang on, as we gyrate between forums, web-sites and manuals to recover Russian motorcycle, electric-start history.

VAZVAZ--1111 "OKA" Starter1111 "OKA" Starter(Sold by Some as an (Sold by Some as an ““AddAdd--OnOn”” ElectricElectric--Start, Requires Modifications)Start, Requires Modifications)

Type 39.3708 / 391.3708 StarterType 39.3708 / 391.3708 Starter--Motor: Motor: 1. Freewheel1. Freewheel2. Stop Ring2. Stop Ring3. Gear3. Gear4. Drive Cover4. Drive Cover5. Lever5. Lever6. Relay Armature6. Relay Armature7. Holding Relay Winding7. Holding Relay Winding8. Pull8. Pull--In Relay WindingIn Relay Winding9. Contact Plate9. Contact Plate10. Relay Cover10. Relay Cover11. Terminal Bolts11. Terminal Bolts12. Cover12. Cover13. Commentator13. Commentator14. Back Cover14. Back Cover15. Brush15. Brush16. Housing16. Housing17. Pole17. Pole18. Rotor or Armature18. Rotor or Armature

BatteryBattery

Starter Starter SolenoidSolenoid


Ignition Ignition SwitchSwitch

Wiring Diagram:Wiring Diagram:1.1. BatteryBattery2.2. StarterStarter3.3. Starter RelayStarter Relay4.4. Ignition SwitchIgnition Switch

Even though it can only be used as an add-on after mechanical modificationsto the Ural, the VAZ-1111 starter-motor serves as an illustration for the CT369.

Specs on 12Specs on 12--Volt Starter Motors Used in UralsVolt Starter Motors Used in UralsDesignationDesignation CT369 CT369

(ST369)(ST369)369.3708, 320.3708369.3708, 320.3708IMZIMZ--8.1248.124--1807518075--1010

CT369CT369ББ(ST369B)(ST369B)369.3708369.3708

CT362A /CT362A /392.3708392.3708

391.3708391.3708or 39.3708 or 39.3708

7102.37087102.3708(similar to (similar to 391.3708)391.3708)

1111.37081111.3708(similar to (similar to 391.3708)391.3708)

CompanyCompany ElectromashElectromash ElectromashElectromash ElectromashElectromash ElectromashElectromash KatekKatek ElectromashElectromash

LocationLocation UkraineUkraine UkraineUkraine UkraineUkraine UkraineUkraine RussiaRussia UkraineUkraine

UseUse Boat Motor "Boat Motor "VihrVihr““inin IrbitIrbit,,"Whirl"Whirl--M"M"

Boat Motor Boat Motor ""VihrVihr““ ininIrbitIrbit,,"Whirl"Whirl--M"M"

EEngines: PDngines: PD--10, 16UD, 10, 16UD, 350 tractors: T350 tractors: T--4, 4, --4A, 4A, --150, 150, --155, 155, --156, DT156, DT--75, 75, --75M, 75M, --75ML,75ML,--75MP, MTZ75MP, MTZ--50L, 50L, --52L, 52L, MTZMTZ--8080--8282

LADA VAZLADA VAZ--1111 1111 ((ВАЗВАЗ 11111111 ОКАОКА))

Rated PowerRated Power 0.552 kW0.552 kW 0.61 kW0.61 kW 0.67 kW0.67 kW 0.9 kW 0.9 kW 0.95 kW0.95 kW 0.92 kW0.92 kW

Nominal VoltageNominal Voltage 1212--VoltsVolts 1212--VoltsVolts 1212--VoltsVolts 1212--VoltsVolts 1212--VoltsVolts 1212--VoltsVolts

# of Gear Teeth# of Gear Teeth 99 99 99 99 99 99

Gear Pressure AngleGear Pressure Angle 2020°° 2020°° 2020°° 1212°° 1212°° 1212°°

Direction of RotationDirection of Rotation LeftLeft LeftLeft LeftLeft LeftLeft LeftLeft LeftLeft

WeightWeight 4.5 kg4.5 kg 4.25 kg4.25 kg 4.4 kg4.4 kg 3.6 kg3.6 kg 4.3 kg4.3 kg

DiameterDiameter 80 mm80 mm 80 mm80 mm 80 mm80 mm 92.5 mm92.5 mm 80 mm80 mm 92.5 mm92.5 mm

Overall LengthOverall Length 224.5 mm224.5 mm 239.5 mm239.5 mm 224.5 mm224.5 mm 207 mm207 mm 234 mm234 mm 206 mm206 mm

Length (front flange Length (front flange to end ofto end of BendixBendix))

67 mm67 mm 67 mm67 mm 67 mm67 mm 63.5 mm63.5 mm 63.5 mm63.5 mm 63.5 mm63.5 mm

Gear ModuleGear Module(starter drive or (starter drive or pinion)pinion)

2.5 mm2.5 mm 2.5 mm2.5 mm 2.5 mm2.5 mm 2.12 mm2.12 mm 2.12 mm2.12 mm 2.12 mm2.12 mm

Length (from front Length (from front flange to end cap)flange to end cap)


Distance between Distance between Mounting HolesMounting Holes

105 mm105 mm 105 mm105 mm 105 mm105 mm 114 mm114 mm 114 mm114 mm 114 mm114 mm

Diameter of Mounting Diameter of Mounting HolesHoles


The 391.3708391.3708, 7102.3708 and 1111.3708 are not exact-replacement starter-motors for the Ural. The mounting holes, gear angle and Bendix length are different.

The High Torque and Poor Metallurgy Accounts The High Torque and Poor Metallurgy Accounts for the Cracked Bell on My Electric Starter for the Cracked Bell on My Electric Starter (2003 Patrol)(2003 Patrol)

CT369CT369

Another Ural Starter (CT369) FailureAnother Ural Starter (CT369) Failure (www.(www.russianironrussianiron.com).com)••Bell Housing on 750cc Electric Starter CrackedBell Housing on 750cc Electric Starter Cracked••New Starter from Stock Is Longer than Previous StarterNew Starter from Stock Is Longer than Previous Starter••KickKick--Start Lever Interferes with Electric Starter BodyStart Lever Interferes with Electric Starter Body

ИМЗ-8.124-18075-10

Several folks have experienced starter-motor casing failures. The choice is between welding the casing back together or purchasing

a new, longer starter-motor, CT369Б.

157 mm / 6.2”

On the Earlier Version (CT369), On the Earlier Version (CT369), the Terminals Are Nearly Flush (10mm) the Terminals Are Nearly Flush (10mm)

with the Endwith the End--Cap.Cap.

CT369CT369ББ ((ИМЗИМЗ--8.1248.124--1807518075))List Price: 7,870List Price: 7,870 рубруб. (. (ruplesruples))www.www.mazeppermazepper..ruru

The CT369Б (ST-369Б) was added by Ural as the IMZ-8.124-18075 (ИМЗИМЗ-8.124-18075) and was used on 650’s, as well as 750’s.

The EndThe End--Cap of the Later Version (CT369Cap of the Later Version (CT369ББ) ) Extends about 25mm Extends about 25mm

beyond the Electrical Terminals.beyond the Electrical Terminals.

CT369CT369ББ Starter for Ural MotorcyclesStarter for Ural Motorcycles

CT369CT369ББ ((CT369B) Later Version of Starter Motor for UralCT369B) Later Version of Starter Motor for Ural

369369ББ.3708.3708

Inscription:Inscription: СТАРТЕРСТАРТЕР (Starter) (Starter) 369369ББ

The EndThe End--Cap of the Later Version (CT369Cap of the Later Version (CT369ББ) Extends ) Extends about 25mm Beyond the Electrical Terminals. about 25mm Beyond the Electrical Terminals.

Electrical Starter for Ural Motorcycle, All ModelsElectrical Starter for Ural Motorcycle, All ModelsPart #: IMZ.1037Part #: IMZ.1037--1807518075Vendor #: 271165375999Vendor #: 271165375999List Price: $224.00List Price: $224.00(compare.(compare.ebayebay.com).com)

The The ““.3708.3708”” is merely the govt. engineering is merely the govt. engineering group code for starters, not really necessary.group code for starters, not really necessary.

Modified KickModified Kick--Start LeversStart Levers•Factory-Supplied, Replacement Motors (CT369Б) Are about 1”Longer than the Original CT369 Starter Motors•No Problem for Russian Outboard Engines (Major Market)–Plenty of Leg-Room in Outboard Engine Compartment

•Three Options for the Longer Starter-Motor on Urals–Remove the Kick-Start Lever Completely (E-Start, No Kick-Start)–F2 Motorcycles Ltd, Can Supply the New, Longer Starter-Motor with a New Kick-Start Lever–Gene “Holopaw” Actually Heated-Up a Kick-Start Lever and Bent One for Me (good job and nice price)

•Starter-Motor Comes with Factory Spacer Plates (two shim plates) and Care Must Be Taken When Fitting to Ensure the Teeth Engage Properly with the Flywheel (try some white graphite)

Electric Starter Electric Starter -- Long. The longer motor is current fitment to all electric startLong. The longer motor is current fitment to all electric start Urals. It can be fitted as a replacement for the Urals. It can be fitted as a replacement for the earlier short type motor, but you will require a new kickearlier short type motor, but you will require a new kick--start lever with a greater offset to clear the back of the startstart lever with a greater offset to clear the back of the starter er motor. motor. Part #: F24320/LONGPart #: F24320/LONGList Price: List Price: ££245.00245.00(www.f2motorcycles.ltd.(www.f2motorcycles.ltd.ukuk))

Kick-StartLeverwith

“bend”

CT362ACT362A

The CT362 starter-motor, also seen on the Internet, mounts on the flange of the gearbox, just as the CT369.

StarterStarter--Motor CTMotor CT--362A (ST362A (ST--362A)362A)• Electric Starter-Motors for Russian Tractors and Special Equipment• Model 362 (ST362A) At 12 volts. • 37.003.084-88 Production Ukraine• 1993 Release

ST362A StarterST362A Starter--MotorMotorPart #: CT362A.3708000Part #: CT362A.3708000Place of Origin:Place of Origin: cheetszyancheetszyan, China, ChinaCar Make: Ukraine Tractor 362ACar Make: Ukraine Tractor 362AVendor ID: 242659521Vendor ID: 242659521((russianrussian..alibabaalibaba.com.com

StarterStarter--Motors:Motors: СТСТ--362362

StarterStarter--Motor Motor СТСТ362362АА, Discontinued, Discontinued((epriborepribor.com).com)

StarterStarter--MotorMotor СТСТ--362362(www.(www.rustehkomplektrustehkomplekt..ruru))

Starter for Porsche 968Starter for Porsche 968CT362A StarterCT362A StarterList Price: 700 rubles List Price: 700 rubles (auto64.(auto64.ruru))

CT362A StarterCT362A Starter--Motor12Motor12--Volt StarterVolt StarterList Price: $105List Price: $105(www.(www.dneprdnepr--kievkiev.com).com)

The CT362 starter-motor has been discontinued.

StarterStarter--Motor 3708 CT362 Motor 3708 CT362 http://www.http://www.ziandziand.com/html/.com/html/ruru/catalog/Starting_Engine/Starter_ST362./catalog/Starting_Engine/Starter_ST362.htmhtm

1. Relay cover 1. Relay cover 2. Gasket 2. Gasket 3. Spring 3. Spring 4. Lock washer 4. Lock washer 5. Washer 5. Washer 6. Bar 6. Bar 7. Washer 7. Washer 8. Washer 8. Washer 9. Spring 9. Spring 10. Washer 10. Washer 11. Bolt pin 11. Bolt pin 12. Stock 12. Stock 13. Nut 13. Nut 14. Washer 14. Washer 15. Yoke 15. Yoke 16. Spring 16. Spring 17. Housing 17. Housing 18. Anchor (Movable Core)18. Anchor (Movable Core)19. Lever 19. Lever 20. Gasket 20. Gasket 21. Cover 21. Cover 22. Washer 22. Washer 23. Lever Axis23. Lever Axis24. Pin 24. Pin 25. Screw 25. Screw 26. Insert (d=9mm, D=13.8, L=13mm)26. Insert (d=9mm, D=13.8, L=13mm)27. Washer 27. Washer 28. Washer 28. Washer 29. Ring 29. Ring

30. Ring 30. Ring 31. Gear 31. Gear 32. Spring 32. Spring 33. Cup Sleeve 33. Cup Sleeve 34. Washer 34. Washer 35. Bearing Cup 35. Bearing Cup 36. Ring 36. Ring 37. Insulated Brush37. Insulated Brush38. Anchor 38. Anchor 39. Brush Holder 39. Brush Holder 40. Brush Bare40. Brush Bare41.41. Insert d= 9mm, D= 13,8, L= 13mmInsert d= 9mm, D= 13,8, L= 13mm42. Ring 42. Ring

43. Cover 43. Cover 44. Spring Brush 44. Spring Brush 45. Gasket 45. Gasket 46. Cap 46. Cap 47. Bolt 47. Bolt 48. Washer 48. Washer 49. Washer 49. Washer 50. Screw 50. Screw 51. Washer 51. Washer 52. Nut 52. Nut 53. Nut 53. Nut 54. Washer 54. Washer 55. Finger 55. Finger 56. Bolt M10x3056. Bolt M10x3057. Washer57. Washer

•Service after 1920 hours of Operation•Follow These Steps:a) Dismantle the Starter.b) Check the Status of the Switch and Clean Them of Dust and Dirt Using Fsuper-Fine Sandpaper•Wipe Collector (Commutator) (11) with a Clean Cloth manifold (11), Soaked in Gasoline•Check Condition of Brushes (5)–Brush Should Fit the Entire Face of the Commutator and Move Freely in the Brush Holders–Check the Pressure Springs on the Brushes•Force Measured by a Dynamometer Should Be between 1000-1400 gauss (10-14 h)

•Oil (Lubricate) the Starter, Neck and Shaft Splines, Thrust-Washers, Pins and the Axis of the Lever•After Assembly, the Gap between the End of the Drive Gear (1) and Thrust Ring (10) on the Armature Shaft (9) when the Solenoid position and the selected actuator backlash toward the collector Needs to be 2 mm. (The gap is not adjustable)•Checking the Starter Idling Current to Consume Less than 50-Amps, while the Speed of Rotation of the Armature Should Be Less than 5,000 rpm•Starter Armature Rotates in Two Bearings, Pressed in the Cover•Two Insulated and Non-Insulated Brush Holder•Engagement with the Flywheel Gear and Transmission of Torque from the Starter to Engine Are Carried Out by Drive Roller (7) Moving Along Helical Slots in the Armature Shaft (9)•Engaging the Gear with the Flywheel Is Caused by a Lever (2) Connected with a Spring-Loaded Solenoid Core

1.1. Engaging (Drive) GearEngaging (Drive) Gear2.2. LeverLever3.3. EarringEarring4.4. SpringSpring5.5. BrushesBrushes6.6. Contact BoltsContact Bolts7.7. Drive CouplingDrive Coupling8.8. CoverCover9.9. Armature Shaft (Rotor)Armature Shaft (Rotor)10.10. Thrust RingThrust Ring11.11. Collector (Collector (CommutatorCommutator))

Servicing the Servicing the СТСТ362 (ST362) 362 (ST362) (tractor(tractor--mtz80mtz80--mtz82.mtz82.ruru))

••KickKick--Starter Lever for IMZStarter Lever for IMZ--8.1248.124--18075 (650/750cc) Electric18075 (650/750cc) Electric--StartStart–#4: 750/650 Kick-Start Lever, '6304045 before 2006, Chrome –#4: 750/650 cc 'IMZ-8.1036-04045-10 Kick-Start Lever from 2006, Chrome

••KickKick--Starter Lever for IMZStarter Lever for IMZ--8.1036 and IMZ8.1036 and IMZ--8.10378.1037–36: IMZ-8.1236-04045-10

•Bell Covers and Gaskets––Starter Cover, Plastic: IMZStarter Cover, Plastic: IMZ--8.8.124124--1811118111––Starter Cover, Aluminum: IMZStarter Cover, Aluminum: IMZ--8.8.10371037--1811118111–– Ural Starter Cover GasketUral Starter Cover Gasket•• List Price: $25.95List Price: $25.95••motorcycleaccessoriesusamotorcycleaccessoriesusa.com.com

PlasticPlastic

AluminumAluminum

GasketGasket

KickKick--Start Levers and Bell for Ural Electric StartersStart Levers and Bell for Ural Electric Starters

Notice the cute little bend in the kick-start lever for later (from 2006)model Urals to handle the longer CT369Б starter motors.

Specify color or chrome when ordering.

Gear Case for Mounting StarterGear Case for Mounting Starter--Motor (650 / 750 cc)Motor (650 / 750 cc)Mounting Flange Mounting Flange for Starterfor Starter--MotorMotor KickKick--Start LeverStart Lever

Gear Shift LeverGear Shift Lever

Bell CoverBell Cover

The gearbox was modified in 1998-1/2 to provide a mounting flange for a starter-motor.

Starter Motor, 12VStarter Motor, 12V(Ural, Dnepr) (Ural, Dnepr) Part #: CT369Part #: CT369Vendor ID: 160917759019Vendor ID: 160917759019List Price: $130.00 USD NewList Price: $130.00 USD New(www.(www.ebayebay.com).com)

Inscription: CT369 12VInscription: CT369 12VТУТУ 37.003.72437.003.724--7777

06 / 200806 / 2008ВИРОБЛЕЮВИРОБЛЕЮ ВВ УКРАУКРАїїННїї

(Made in Ukraine)(Made in Ukraine)

Electric Starter (Electric Starter (СтартерСтартер УралУрал электроэлектро))

The CT369 is the “A” version of the Ural electric-start motor (shorter version).

369369ББ.3708 and 392.3708.3708 and 392.3708The EndThe End--Cap of the Later Version (CT369Cap of the Later Version (CT369ББ) Extends ) Extends

about 25mm Beyond the Electrical Terminals. about 25mm Beyond the Electrical Terminals.

Electric Starter, Dnepr (369Electric Starter, Dnepr (369ББ.3708) .3708) Part #: 003.900Part #: 003.900List Price: List Price: €€150.00150.00(www.(www.oldtimergarageoldtimergarage..eueu))

369369ББ.3708.3708

Electric starter 12V, UralElectric starter 12V, UralVendor ID: 003.899Vendor ID: 003.899Part #: IMZPart #: IMZ--8.1248.124--1807518075--1010List Price: List Price: €€180.00180.00(www.(www.oldtimergarageoldtimergarage..eueu))

392.3708392.3708

Old Timer Garage supplies two types of starter-motors, the 392.3708 for the Ural, 392.3708 for the Ural, whichwhich is the shorter version; and the 369369ББ.3708 for the Dnepr, .3708 for the Dnepr,

which is the longer which is the longer version).

CT369CT369ББ Electric StartersElectric Starters

Electric StarterElectric Starter(Dnepr)(Dnepr)Part #: 369Part #: 369ББ.3708.3708Vendor ID: 003.900Vendor ID: 003.900List Price: List Price: €€150.00150.00(www.(www.oldtimergarageoldtimergarage..eueu))

(Ural Motorcycle 650 /750)(Ural Motorcycle 650 /750)Part #: IMZPart #: IMZ--8.1248.124--1807518075(www.auto(www.auto--elektrikelektrik.de).de)

Inscription: 369Inscription: 369ББ (369B) 12.2011(369B) 12.2011

Electric Starter Electric Starter -- Long. The longer motor is current fitment to all electric Long. The longer motor is current fitment to all electric start Urals. It can be fitted as a replacement for the earlier sstart Urals. It can be fitted as a replacement for the earlier short type hort type motor but you will require a new kickmotor but you will require a new kick--start lever with a greater offset to start lever with a greater offset to clear the back of the starter motor. clear the back of the starter motor. Part #: F24320/LONGPart #: F24320/LONGList Price: List Price: ££245.00245.00(www.f2motorcycles.ltd.(www.f2motorcycles.ltd.ukuk))

Electric Starter Electric Starter (Ural 750/650)(Ural 750/650)Part #: IMZPart #: IMZ--8.1248.124--1807518075Vendor ID: 1725Vendor ID: 1725List Price: List Price: €€245.14245.14(www.(www.uralural--europaeuropa.com).com)

Electric Starter Electric Starter Part #: IMZPart #: IMZ--8.1248.124--18075 18075 Engine: 650/750 Engine: 650/750 List Price: $300 List Price: $300 http://www.http://www.uralural.ca/parts.html.ca/parts.html

The CT369The CT369ББ Electric StartersElectric Starters are the newer, longer electric starters for Urals.

Suppliers of Ural Electric StartersSuppliers of Ural Electric Starters

Starter Motor, 12VStarter Motor, 12V(Dnepr, Ural)(Dnepr, Ural)List Price: $120.00List Price: $120.00(www.(www.ebayebay.com).com)

Ural Electric StarterUral Electric StarterList Price: 4,999 rubles List Price: 4,999 rubles (www.mc78.(www.mc78.ruru))ororUral Electric StarterUral Electric StarterList Price: 4,350 rubles List Price: 4,350 rubles (750cc.(750cc.ruru))

369.3708369.3708

Starter 369.3708 Whirlwind (ELECTROMASH)Starter 369.3708 Whirlwind (ELECTROMASH)Vendor ID: Vendor ID: 11651165--ElmashElmashMfgrMfgr: : ELECTROMASHELECTROMASH KhersonKhersonList Price: $621.94List Price: $621.94((ruavtoruavto.com..com.uaua))ororOEM Ural Starter for All 750/650ccOEM Ural Starter for All 750/650ccImproved, Late Model (Longer)Improved, Late Model (Longer)List Price: $145List Price: $145((hotspringshotsprings--arar..americanlistedamericanlisted.com).com)

Starter, Whirlwind (Starter, Whirlwind (ElectromashElectromash))Part #: 369.3708 Part #: 369.3708 List Price: $418.00List Price: $418.00(shop.(shop.prizmaavtoprizmaavto.com..com.uaua))

Starter Motor for Dnepr 650ccStarter Motor for Dnepr 650ccVendor ID: S2072 Vendor ID: S2072 List Price: List Price: €€189.00189.00(www.(www.uralural--zentralezentrale.de).de)

Unless the vendor includes the part # (CT369 or CT369Б), it’s hard to tell if the starter motor is long. The best way is to measure the motor

from the base of the flange to the end of the end-cap.

Common Problems for Starter CTCommon Problems for Starter CT--369 and Possible Solutions369 and Possible SolutionsExternal manifestation of External manifestation of

faults faults Probable cause Probable cause Remedy Remedy

When pulling the starter When pulling the starter relay, but the starter does relay, but the starter does not crank or cranks the not crank or cranks the flywheel slowly flywheel slowly

Lack of reliable contacts in places Lack of reliable contacts in places connecting wires to the starter and connecting wires to the starter and

battery battery

Check the contactsCheck the contacts

Stuck or worn brushes Stuck or worn brushes Eliminate hang or replace worn brushes Eliminate hang or replace worn brushes

Dirty collector Dirty collector Wipe or strip the collector Wipe or strip the collector

Discharged or defective battery Discharged or defective battery Recharge or replace battery Recharge or replace battery

Anchor starter spinning but Anchor starter spinning but not cranking the flywheel not cranking the flywheel

Stalled freewheel drive starter Stalled freewheel drive starter Replace drive Replace drive

When the starter is audible When the starter is audible rattle (gear does not rattle (gear does not engage with the rim engage with the rim flywheel) flywheel)

Clogged flywheel teeth Clogged flywheel teeth Strip Nick on the teeth or replace a crown Strip Nick on the teeth or replace a crown

Clogged starter gear teeth Clogged starter gear teeth Clean the drive or replace Nick Clean the drive or replace Nick

The actuator moves the shaft tightly The actuator moves the shaft tightly anchor anchor

Wipe the slot drive shaft and bushing cloth Wipe the slot drive shaft and bushing cloth lightly soaked in gasoline, and grease motorists lightly soaked in gasoline, and grease motorists

After starting the starter After starting the starter motor does not turn off motor does not turn off

Jamming drive shaft starter armature Jamming drive shaft starter armature Dismantle the starter and remove the cause of Dismantle the starter and remove the cause of seizure seizure

Jamming anchor magnetic switch Jamming anchor magnetic switch Remove the cause of seizure Remove the cause of seizure

The most common problems include the lack of a starter or weak cranking the flywheel when the solenoid pulls in. The main reason for this may be a problem with the electrical circuit: bad contacts in the starter or the battery

terminals, discharging, worn or hung brushes, or oxidation of the commutator.

1998 Ural Deco with Hitachi Starter1998 Ural Deco with Hitachi Starter--GeneratorGenerator•Late '98 was the first of the Electric Starter for Ural

FrontFront

FrontFront

1818--Amp Hitachi StarterAmp Hitachi Starter--GeneratorGenerator

Cha

rge

Cha

rge

++

--

IgnitionIgnitionSwitchSwitch

IsolationIsolationSwitchSwitch

StarterStarterSolenoidSolenoid

MomentaryMomentaryStarter ButtonStarter Button

(black, on handlebar)(black, on handlebar)

Voltage RegulatorVoltage Regulator

DiodeDiode

1010ΩΩ ResistorResistor

3030ΩΩ ResistorResistor

DD--

.

..

..

.

F2F2

Regulator CoilRegulator Coil

F1F1

Beefy Beefy TerminalsTerminals

On many models, the silicone Diode is On many models, the silicone Diode is mounted across the large terminals of mounted across the large terminals of

the Starter Solenoidthe Starter Solenoid

Starting

Starting

Note: Two wires to Note: Two wires to handlebar button.handlebar button.

SmallSmallRedRedWireWire

LargeLargeWhiteWhiteWireWire

Small Small BlackBlackWireWire

LargeLargeGreyGreyWireWire

Middle ProngMiddle ProngOf Top RowOf Top Row FuseFuse

to Horn & to Horn & Brake LightsBrake Lig

#2#2hts

1212--VoltVoltBatteryBattery

Generator Fault LampGenerator Fault Lamp(red, lights when battery voltage (red, lights when battery voltage is greater than charging voltageis greater than charging voltageextinguishes at high rpm when extinguishes at high rpm when

charging)

SS

charging)Installed on Some Models,Installed on Some Models,Used to Keep Battery from Used to Keep Battery from

Discharging Over LongDischarging Over Long--Term StorageTerm Storage(if not present, replaced with a wire)(if not present, replaced with a wire) D+D+

A1A1 DFDF

Hitachi Hitachi StarterStarter--GeneratorGenerator

(18(18--Amp, 0.9HPAmp, 0.9HPGSB107GSB107--04A,04A,

FiveFive--Terminal)Terminal)Up Up tocChargingtocCharging voltage, voltage,

the winding current is the winding current is max, as the FF terminal is max, as the FF terminal is effectively grounded. As effectively grounded. As Voltage at D+ increases, Voltage at D+ increases,

the relay pullsthe relay pulls--In, In, reducing the winding reducing the winding

current by placing a 10current by placing a 10ΩΩresistor in series.resistor in series.

DFDF

A2A2Armature (A)Armature (A)

(Rotor) Field (F) WindingField (F) Winding(Stator)(Rotor) (Stator)

DT Stands for DT Stands for Dynamo FieldDynamo Field

Optional Electric Start on Early 650cc Urals Optional Electric Start on Early 650cc Urals (2001 Owner(2001 Owner’’s Manual)s Manual)

.

Notice, starterNotice, starter--motor geared to flywheel.motor geared to flywheel.

In 1998-1/2, Ural offered electric-start for its 650cc bikes. It used the CT369 starter-motor from the Whirlwind (Vortex) outboard engines,

popular in the USSR, and built in Irbit (home-town of Ural).

Up until 2006, Urals used the CT369 electric starters, which allowed straight kick-start levers. After that, the kick-start levers needed to be

modified to avoid interference with the longer replacement starter-motor.

20032003--2007 Owners Manual (Gear Up, Patrol, Tourist)2007 Owners Manual (Gear Up, Patrol, Tourist)

Ural 650/750cc Starter/Alternator Circuit (2002Ural 650/750cc Starter/Alternator Circuit (2002--2003) with 352003) with 35--Amp AlternatorAmp Alternator

.

.

Connector Pin

Male Female

85 86 30 87 85 86 30 87

Pos +

Neg -

Red(Alternator

Fault)

RY-115Electric Start

Relay #2(Normally Open)

Starter Motor

12 VoltBattery

Momentary“Start”Button

Rocker-Arm“Run / Kill”

Switch

Right Handlebar

Headlight Cavity

6 5 1 2 3

white

4

3

1

2

grn / red

yel / red

red

pnk/ blk IgnitionModule

+ -

In-Line Fuse #1

+ FaultTerminal(spade)

Starter Solenoid

Notes:1. In-Line Fuse #1 (15A) for Turn Signal and

Neutral Indicator Lamp.2. Fuse Block #4 Fuse (5A) for Ignition and

Electric Start Relays.

8586

30

87

“Run”“Kill”

(0V.: Engine not running,+12V.: Engine running and

Alternator working.”)

“Start”

top

bottom

35 Amp Russian(Hand Grenade)

Brakes

Headlites

Run Lites

+ Main Output(ring)

red

gray

(back-side)(face-side)

red

9-pin Connector



blackredwhitegreen(+12V. in “Run” position)

Neutral Switch

largewhite

Green(Neutral)

largeblack

blue

green

redIgnitionSwitch Chassis

Ground

(+12V. When Ignition Switch on “Run”)

Fuse BlockIgnition KeyTerminal

Replacement 12Replacement 12--Volt Starter on My 2003 PatrolVolt Starter on My 2003 Patrol

The CT369The CT369ББ (replacement) required a (replacement) required a “”“”bentbent”” kickkick--start lever start lever to avoid interference. to avoid interference.

CT369Б (ST369B)

Ural 750cc Starter/Alternator Circuit (2004Ural 750cc Starter/Alternator Circuit (2004--2005) with N2005) with N--D 55D 55--Amp AlternatorAmp Alternator

.

Connector Pin

Male Female

85 86 30 87 85 86 30 87

Pos +

Neg -






12 VoltBattery

Headlight Cavity

6 5 1 2 3

black

white

red

4

3

1

2

red

blue

Starter SolenoidStarter Solenoid

Notes:1. In-Line Fuse #1 (15A) for Turn Signal

and Neutral Indicator Lamp.2. Fuse Block #4 Fuse (5A) for Ignition &

Electric Start Relays.

(+12V. when Ignition Switch on “Run”)

(0V.: Engine not running+12V.: Engine running and

Alternator working.”)

bottom

Notes:1. Two Start Relays (RY-115)2. In-Line Fuse #1 deleted mid-2005

55 Amp Nippon55 Amp Nippon--Denso Denso AlternatorAlternator + Main

Output

IG(ignition)

L(lamp)

L

IG

green

Brakes

Headlites

Run Lites

(+12V. in “Run” position)

.

Right Handlebar

grn / red

yel / red

red

pnk/ blk IgnitionModule

+ -

In-Line Fuse #1

8586

30

87

“Run”“Kill”

“Start”

top

red

gray

(back-side)(face-side)

9-pin Connector .


Switch


whitelargegreyNeutral

Switch largeblack

Green(Neutral)

Red(Alternator

Fault) red

red

IgnitionSwitch Chassis

Ground

Fuse BlockIgnition Key Terminalblack

Ural 750cc Starter Circuit (2006Ural 750cc Starter Circuit (2006--2007) 2007) SingleSingle--Relay

.

Connector Pin

Male Female

85 86 30 87

Pos +

Neg -

RY-115Electric Start Relay

(Normally Open)


55 Amp55 AmpNipponNippon--Denso AlternatorDenso Alternator

12 VoltBattery

5 6 1 2 3

16 red

15A

5A

15A

5A

grn/red

yel/red

red

pnk/blkDucati

IgnitionModule

+ -

+ Main Output

8586

30

87

GFED

18 blk/red

18 brn/red

18 brn/red



Switch “Kill”

(+12V. in ”Run” position)

“Start”

“Run”

L

IG

Notes:1. Single Start Relay (RY-115)2. ND Alternator added 20043. In-Line Fuse #1 Deleted mid-2005

Relay

Right Handlebar

Starter SolenoidStarter Solenoid

Headlight Cavity18 brn/red

10-pin Connector 18 blu/wht 16 wht8 red

18 pnk

12 redNeutral SwitchGreen

(Neutral) 18 blk/red

Fuse BlockRed

(Alternator Fault)

18 pnk/blk8 blk18 pnk/blk

Terminal

Ignition Key

12 red

IgnitionSwitch

14

Note: # in front of wire color is AWG wire size.

18 bluChassisGround

bluIG

(ignition)

L(lamp)

14 blu

Ural (Ural (УралУрал) ) 20102010--2011 (750cc)2011 (750cc)

55 Amp55 AmpNipponNippon--Denso AlternatorDenso Alternator

StarterStarter--Motor Motor and Solenoidand Solenoid

Ural (Ural (УралУрал) ) IMZIMZ--8.1037 (with Electric8.1037 (with Electric--Start)Start)

Ural (Урал) - Dnepr (Днепр Electric Starters · Ernie Franke [email protected] 09 /...

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Transcript of Ural (Урал) - Dnepr (Днепр Electric Starters · Ernie Franke [email protected] 09 /...