Ural Transmission Finished!

Seventeen days after disassembly, I actually remembered how to put the transmission together. And there were no parts left over. At least none that I could find. I used silicone sealer between the two halves of the case and followed the procedure that Van Le of lemoto.info to "set" the kick starter spring and adjust the upshift and downshift stop screws. I did go through the gears on the bench to make sure it shifted into all of the gears though reverse seems a bit more difficult to get into than before. Reassembling the case took a couple of attempts as I didn't have the kick starter spring procedure memorized and had to pull it to reset the spring to a known position. The specified torque for the case bolts is only 6.2 newton-meters which translates to 55 inch-pounds. This is lower than the lowest setting on my ⅜" drive torque wrench. So I just hand tightened the bolts.

I took the opportunity to grease the transmission input shaft with a mixture of Honda Moly 60 and thick axle grease. The input shaft splines show almost no wear as do the clutch discs. The input shaft is still the original but the clutch discs were changed during the engine rebuild. It was somewhat of a challenge to get the square end of the clutch release rod into the pressure plate but after digging through my tools I found that a nut driver fits onto the end of the rod perfectly and allows me to move the shaft around while rotating the flywheel with the kick starter.

I think it took longer to reinstall the rear swingarm than installing the transmission. It required the removal of the rear shocks to get the swingarm pivots to line up. It's about 99% finished. I took it for a test ride and realized that I had forgotten to attach the rear brake spring. Minor detail. The transmission shifts cleanly and no more popping out of gear. I still need to attach the brake spring and adjust the rear brakes. Then it'll be time for a real test ride.

Update - It runs just fine and the shifts seem more positive than ever. Ran it up and down through the gears tonight and then brought it back into the garage to change the engine oil. The last time I changed it I didn't have a filter handy. Upon examination, I'm glad that I changed third gear as well as there was significant wear where the slider engaged the gear that wasn't noticeable until I could compare it with the new gear.