russian motorcycles brembo disc brake systemsup.picr.de/18504456bf.pdf · russian motorcycles...

Russian MotorcyclesRussian MotorcyclesBremboBrembo Disc Brake SystemsDisc Brake Systems(See also Russian Motorcycle Brake Lights and Switches)(See also Russian Motorcycle Brake Lights and Switches)

Ernie FrankeErnie [email protected]@tampabay.rr.com January 2012January 2012

Ural Ural BremboBrembo BrakesBrakes• Ural Equipped with Hydraulic Disc Brake in Front, with Manual Shoe-Type Brakes in Rear

and Sidecar–Front Wheel Hydraulic Disc Brake Consists of Caliper, Brake Pads and Disc–Front Brake Responsible for 70% of Total Stopping Power–Sidecar Brake Connected to Rear Brake Pedal–Spare Tire, Used to Directly Replace either Rear Wheel or Sidecar Wheel, but Disc Brake

Prevents All-Around Replacement, as in the Old Days when Ural Used a Drum Front Brake

•WARNING in Owner’s Manual: Never Use Front Brake to Stop when Motorcycle Is Moving in Reverse–Severe Damage to Front Brake Caliper and Mounting Plate Will Occur

•Order of Presentation–Brembo (Italy) Disc Brakes–Calipers–Replaceable Pads–Hydraulic Reservoir–Hydraulic Brake Line–Ural by Year and Model–Fixed / Floating Rotor Disc: New and Old

• Front Disc Brakes Require Periodic Inspection, but Do Not Require Adjustment–Brake Pads Inspected by Removing Dust Shield from Top of Caliper–Check Thickness Pads: Should Be Replaced when Less than 1/8” of Pad Remaining on

Either Pad–Brake Hose Inspected for Leaks and Cracks along Length of Hose and Banjo Fittings on

Both Ends

Brembo Brakes are found on modern Urals (2003+), but not on Dneprs.

Ural Disc Brake PartsUral Disc Brake PartsStainless Steel, Braided Cable, Hydraulic Brake Line (Hose)Stainless Steel, Braided Cable, Hydraulic Brake Line (Hose)

Bleed ValveBleed Valve

Disc RotorDisc Rotor

““FloatingFloating”” Disc Rivets (Buttons)Disc Rivets (Buttons)

Banjo FittingBanjo Fitting

Brake Pad Dust CoverBrake Pad Dust CoverPins for Retaining Brake PadsPins for Retaining Brake Pads

Brake Disc Evolution by Part NumbersBrake Disc Evolution by Part Numbers• Front Disc Brake Caliper Introduced to Urals in 2003– Front Brake Caliper (Brembo): IMZ-8.1238-27005-01 (Brembo 20.6800.10)

• Brake Rotor Disc– 2003-2007: IMZ-8.1037-06026 (Russian) 300 mm diameter

• Not Available Anymore: Upgrade Using Brembo Items;– 8 IMZ-8.1037-06026-10 Brembo Floating Rotor Installed from 2007– 8a IMZ-8.1037-06132 (steel) IMZ-8.1037-06132-10 (aluminum) Brembo Brake Adapter - Used to Mount Brembo

Rotor (adapter plate has width to it to shim the rotor out from the hub)–Brake Disc (2007-2009): IMZ-8.1037-06026-10 (Brembo 08.4899.72) 320 mm diameter

• Disc a Little Bit Thinner• European Recall in Fall 2010 to Add Washers beneath Rotor Screws–Original Bolts Too Long in Some Cases–Bolts Fit Brembo Discs, which Were Thicker

–Brake Disc (2010+): IMZ-8.1037-06026-NG (www.ngbrakedisc.com) 295 mm diameter• Front Brake Switch–Brake Switch (Brembo) Up to 2006: IMZ-8.1037-17048-07–Brake Switch (Brembo) 2007-2008: IMZ-8.1037-17048-2007, IMZ-8.1037-17048-EU–Brake Switch (Brembo) 2009+: IMZ-8.1037-17048-2009 (Brembo 10.4671.61)

• Front Master Brake Cylinder (MBC) Assembly– Front Master Brake Cylinder: IMZ-8.1238-27003-10 (Brembo 10.4620.79)

• Hydraulic Brake Line (Hose)–Rubber Brake Hose (2003-2007)• IMZ-8.1037-27014-10 (for Telescopic Fork)• IMZ-8.1037-27015 (for Leading Link)

–Steel-Flex Braided Brake, incl. banjo bolts and sealing rings (2008+): IMZ-8.1037-27015-08• Front Brake Pads–Set of Two Brake Pads: IMZ-8.1238-27097 (Brembo 107.6708.10 Organic Compound)–Set of Two Brake Pads: Brembo Sintered: 07.6708.02–Set of Two EBC Double-H Sintered Metal Brake Pads: FA244HH

• Conversion Kit for Drum Brake to Brembo Disc Brake–Complete Assy. Converts Russian Drum Brake to a 2007-Style Brembo Disc Brake, Includes All Components (front

wheel, fork leg, rotor, caliper mounts, reaction link, all hardware, etc.)– Front Forks– Telescopic Fork (Russian): IMZ-8.103-08001-30 (750 cc)– Leading Link Fork Assy for Disc Brake from 2006: IMZ-8.1037-08001-40– Leading Link Fork Assy for Disc Brake from 2007: IMZ-8.1037-08001-41– Leading Link Fork Assy for Disc Brake from 2008: IMZ-8.1037-08001-08– Leading Link Fork Assy for Disc Brake from 2011: IMZ-8.1037-08001-90-Color

As you can see, it’s hard to keep up with the changes associated with Brembo disc brakes.

Disc Brake Evolution on Urals (2003Disc Brake Evolution on Urals (2003--2004)2004)

•• 2004 Patrol2004 PatrolRubber Brake HoseRubber Brake HoseFixed Rotor DiscFixed Rotor DiscRightRight--Hand CaliperHand Caliper


•• 2003 Tourist2003 TouristRubber Brake HoseRubber Brake HoseFixed Rotor DiscFixed Rotor DiscRightRight--Hand CaliperHand Caliper

•• 2004 2004 TroykaTroykaRubber Brake HoseRubber Brake HoseFixed Rotor DiscFixed Rotor DiscTelescopic ForkTelescopic ForkLeftLeft--Hand CaliperHand Caliper

•• 2004 Tourist2004 TouristRubber Brake HoseRubber Brake HoseFixed Rotor DiscFixed Rotor DiscRightRight--Hand CaliperHand Caliper

It takes a heap of investigation to determine the evolutionary path of such a simple arrangement.

•• 2005 Retro2005 RetroRubber Brake HoseRubber Brake HoseFixed Rotor DiscFixed Rotor DiscLeftLeft--Hand CaliperHand Caliper

•• 2005 2005 TroykaTroykaRubber Brake HoseRubber Brake HoseFixed Rotor DiscFixed Rotor DiscLeftLeft--Hand CaliperHand Caliper


•• 2005 Gear2005 Gear--UpUpRubber Brake HoseRubber Brake HoseFixed Rotor DiscFixed Rotor DiscRightRight--Hand CaliperHand Caliper


•• 2006 Gear2006 Gear--UpUpRubber Brake HoseRubber Brake HoseFixed Rotor DiscFixed Rotor DiscRightRight--Hand CaliperHand Caliper•• 2006 2006 TroykaTroyka

Rubber Brake HoseRubber Brake HoseFixed Rotor DiscFixed Rotor DiscLeftLeft--Hand CaliperHand Caliper

The forks’ leading link design, though archaic, actually works better for sidecar handling than do conventional telescopic forks.



•• 2007 2007 PustinjaPustinja Floating Floating Rotor DiskRotor DiskRightRight--Hand CaliperHand Caliper •• 2007 Retro2007 Retro

Floating Rotor DiskFloating Rotor DiskRightRight--Hand CaliperHand Caliper

•• 2008 Patrol2008 PatrolFloating Rotor DiskFloating Rotor Disk

RightRight--Hand CaliperHand Caliper

•• 2008 Tourist2008 TouristFloating Rotor DiskFloating Rotor Disk


•• 2008 Gear2008 Gear--UpUpFloating Rotor DiskFloating Rotor Disk

RightRight--Hand CaliperHand Caliper•• 2008 Retro2008 Retro

Floating Rotor DiskFloating Rotor DiskLeftLeft--Hand CaliperHand Caliper

•• 2007 Patrol2007 PatrolFloating Rotor DiskFloating Rotor DiskNew Brake Hose Routing New Brake Hose Routing with Retaining Clipswith Retaining Clips


Floating Disc(Note Rivets)

The evolution of disc brakes involves rotors, calipers, brake lines, switches, pads, master cylinders and conversion kits.


•• 2009 Patrol2009 PatrolFloating Rotor DiskFloating Rotor DiskRightRight--Hand CaliperHand Caliper

•• 2009 Gear2009 Gear--UpUpFloating Rotor DiskFloating Rotor DiskRightRight--Hand CaliperHand Caliper

•• 2009 Sahara 2009 Sahara Floating Rotor DiskFloating Rotor DiskRightRight--Hand CaliperHand Caliper

•• 2009 Retro2009 RetroFloating Rotor DiskFloating Rotor DiskLeftLeft--Hand CaliperHand Caliper

•• 2009 Ural T2009 Ural TFloating Rotor DiskFloating Rotor DiskRightRight--Hand CaliperHand Caliper

•• 2010 Red October2010 Red OctoberFloating Rotor DiskFloating Rotor DiskRightRight--Hand CaliperHand Caliper

•• 2011 Patrol2011 PatrolFloating Rotor DiskFloating Rotor DiskRightRight--Hand CaliperHand Caliper

•• 2011 M2011 M--7070Floating Rotor Disk on Floating Rotor Disk on Telescopic ForkTelescopic ForkRightRight--Hand CaliperHand CaliperSteelSteel--Braided HoseBraided Hose

•Leading Link Fork–Used on Patrol, Gear-Up and Tourist–Mounts Brembo Caliper on Right-Hand Side

•Telescopic Fork–Used on Retro, Troyka–Mounts Brembo Caliper on Left-Hand Side•Except for Ural T and M-70 (Telescopic Fork and Right-Hand Caliper)

TelescopicTelescopic--Type ForkType Fork Leading Link, LeverLeading Link, Lever--Type ForkType Fork

LeadingLeading--Link versus Telescopic Front ForksLink versus Telescopic Front Forks

Differing front forks require differing brake solutions.

OwnerOwner’’s Manualss Manuals

Leading Link ForkLeading Link ForkRightRight--Hand CaliperHand CaliperRubber Brake LineRubber Brake Line

Telescopic ForkTelescopic ForkLeftLeft--Hand CaliperHand CaliperRubber Brake LineRubber Brake Line

IMZIMZ--8.10378.1037--0800108001--11 (Paoli)11 (Paoli)IMZIMZ--8.10378.1037--0800108001--40 (from 2006)40 (from 2006)

IMZIMZ--8.10378.1037--0800108001--41 (from 2007)41 (from 2007)

IMZIMZ--8.10378.1037--0800108001--08 (f08 (from 2008)rom 2008)

IMZIMZ--8.10378.1037--0800108001--9090--Color (2010Color (2010) (Bearing Type)) (Bearing Type)

IMZIMZ--8.10378.1037--0800108001--3 (up to 20073 (up to 2007) (Bushing Type)) (Bushing Type)

IMZIMZ--8.10368.1036--08001 (Retro from 08001 (Retro from 2010)2010)

IMZIMZ--8.10378.1037--0800108001--50 (for EU)50 (for EU)Front ForkFront Fork

IMZIMZ--8.12368.1236--2700127001IMZIMZ--8.10378.1037--2700127001Front Wheel Bracket Mounting SetFront Wheel Bracket Mounting Set

IMZIMZ--8. 1268. 126--2701427014--1010IMZIMZ--8.10378.1037--2701527015Brake LineBrake Line

Telescopic Front ForkTelescopic Front ForkLeading Link ForkLeading Link ForkComponent (750 cc)Component (750 cc)

2006-2011 Ural Maintenance Manuals

Telescopic Fork (Retro)Telescopic Fork (Retro)Brembo Brembo Caliper on Left SideCaliper on Left SideFloating Rotor DiscFloating Rotor DiscRubber Brake LineRubber Brake Line

Caution: The maintenance manuals for Patrol, Gear-Up and Tourist show figures that may not indicate the correct year or model.

Ural Changes and Upgrades forUral Changes and Upgrades for BremboBrembo Brakes: Brakes: TimelineTimeline

2003 20112007

Paoli Fork Introduced

20052004 2006 2008 2009 2010time

Brembo Fixed Disc Introduced to Front Brake

(non-floating disc) NG-Manufactured Disc, Still using Brembo Caliper

Brembo Floating Disc on All Models(IMZ-8.1037-08001-08 Leading Link

Fork Assembly)

Floating Disc on Retro/TroykaFront Brake

Ural Engine Increased Engine from 650cc to 750cc

Steel Flex-Braid Brake Line Introduced

Brembo Fixed Disc(IMZ-8.1037-08001 Leading Link Fork Assembly)

‘06 and Earlier Urals with Disc Brakes Use Same Fork as Early Drum Brake Units

(IMZ-8.103-08001 Leading Link Fork Assembly)

Brembo full-floating disc proved more than capable of stoppingthe 700-plus pound bike (along with rider and passenger) with ease.

Disc Brake Evolution on UralsDisc Brake Evolution on Urals

•• 2010 Solo 2010 Solo sT sT (solo tour)(solo tour)

•• 2010 Patrol2010 Patrol•• Newer SteelNewer Steel--Braid Hydraulic LineBraid Hydraulic Line

•• 2011 Patrol / Gear2011 Patrol / Gear--UpUp•• SteelSteel--Braid Hydraulic LineBraid Hydraulic Line

•• 2009 2009 Ural GearUral Gear--Up / Up / Tourist / Patrol / WolfTourist / Patrol / Wolf

•• 2009 Ural2009 Ural--TT

Floating Disc(Note Rivets)

Marzocchi Telescopic Fork on sT

FlexibleFlexible--BraidBraidBrake LineBrake Line

Disc Brakes Disc Brakes (2000 How Stuff Works)(2000 How Stuff Works)

•Disc Brake Similar to Brakes on a Bicycle–Bicycle Brakes Have Caliper, which Squeeze Brake Pads against Wheel–Motorcycle Disc Brake Pads Squeeze Rotor instead of Wheel–Force Transmitted Hydraulically, Instead of thru a Wire Cable–Friction between Pads and Disc Slows Disc Down

UralUral’’ss Floating (Floating (two-piece) RotorRotor• Two Types of Motorcycle Brake Discs: Fixed (2003-2006) & Floating (2007+)• Fixed Brake Disc (introduced on 2003 Urals)–One Piece Disc• Brake Pad Contact Face and Wheel Mounting Face All Part of Same Piece of Metal

–Relatively Inexpensive to Produce–Perform Perfectly Well – If Subjected to Serious, Possibly Unable to Dilate or Expand

• Floating Brake Disc (introduced on 2007 Urals)–Constructed in Two Parts• Aluminum Center Part Fixed to Motorcycle Wheel and Stainless Rotor

–When Rotor Subjected to Serious Heat, It Expands–By Allowing It to Float Separately from the Mounting Face, It Is Free to Expand and Shrink at Will

without Being Constrained by Its Mounting–Expansion Takes Place in All Directions at Once and Not Constrained• If you prevent this from happening in one direction (by fixing it on its mounting face) it has no

choice but to warp, so floating discs are made in two parts to allow the discs to expand and prevent them from warping. This is mainly a high performance type brake disc.

• Which is better?–Fixed disc is much better for high-performance braking. For daily driving, floating disc is good. And

why most car manufacturers prefer floating discs? Becuase these are easier to design and fabricate, thus lower manufacturing costs.–Floating rotors are two piece rotors that has the hub and the disc joined by bolts. That way you can

have lightweight alloys for the hub and a different compound/fabrication for the disc and have the best of both worlds. Also heat dissipates faster in floating rotors, why I'm not sure.–The main complain about floating rotors is that they're much louder than normal rotors because

they're two-piece, thus allowing more noise to be eminate when the disc "vibrate" under braking.

The floating disc heats up more uniformly, and the controlled float which is present allows for the differential expansion of the hot disc,

and the relatively cool aluminum bell. This allows the disc to be used under severe conditions without having a detrimental effect.

BemboBembo Directional BrakesDirectional Brakes•Are Brembo Calipers Directional?–Brembo's calipers are directional, due to the use of differential piston sizes (30/40 mm).

The leading pistons are smaller in diameter in order to combat uneven wear of the brake pads. Upon close examination of the caliper, you will find a small arrow cast in place which denotes the direction of disc rotation. Additionally, when mounted on the vehicle, the bleed screw must be at the top of the caliper.

•Brembo Brakes in Australia–The disc brake is one of the reasons that sidecar Urals cannot be sold in Australia.

Certifying engineers, DOTARS and the various state and territory rego authorities all take a rather dim view of brake components rubbing or bending when applied in reverse. And when that then ceases to allow the front brake to work in the forward direction, it is referred to as a catastrophic failure. Now, while putting a warning in the owner's manual not to use the front brake in reverse may work in Europe, the USA and Canada, it doesn't cut it here for a vehicle fitted with a reverse gear in Australia. (http://http://bcozzbcozz.multiply.com/journal/item/345).multiply.com/journal/item/345)

2010 Catalog Hydraulic Disc Brakes2010 Catalog Hydraulic Disc Brakes ((uralnwcouralnwco..ipoweripower.com).com)

1Brake Stop-Light SwitchIMZ-8.1037-17048-2009

1Brake Stop-Light Switch (Brembo 10.4761.61)IMZ-8.1037-17048-20071Brake Stop-Light Switch italian for European wire harness 2007IMZ-8.1037-17048-EU

1LeverComponent: 3040.04.00 (650/750

1Brake Stop-Light SwitchComponent: 2218.20.00 (650/750)

1Front Brake Hose, RubberIMZ-8.1037-27016 (650/750)3

8Sealing Washer10284460 (650/750)7

1AdapterIMZ-8.125-272285

1

42

Kit of 2 PadsKit of 2 Pads1

11

1QuantityQuantity

IMZ-8.1037-27001-01

IMZ-8.1037-27186IMZ-8.1037-27187

EBC padsIMZ-8.1238-27097IMZ-8.1037-27015-08

IMZ-8.1037-27015IMZ-8.1238-27005-01

IMZ-8.1238-27003Part #Part #

Brake Pads (Brembo 107.6708.10)4Steel-Flex Brake Line (2008+)or 3A

Front Brake Hose, Rubber (2003-2007)3

Coupling Bolt (Banjo Fitting)6Sealing Washer7

EBC Brake Padsor 4A

Brembo Hydraulic Brake Assembly8

Caliper (Brembo 20.6800.10)2

Master Cylinder Assembly (Brembo 10.4620.79)1DescriptionDescriptionItem #Item #

2010

650/750 cc

Front Disc Brake Part Evolution

• 2008-2010• #7 Wheel Hub: IMZ-8.1037-06020-10• #8 Front Brake Rotor: IMZ-8.1037-06026-10

(Brembo 08.4899.72)• #20 Screw M8x16 DIN 6912 M8x16• #21 Rotor Spacer (Intermediate Bushing):

IMZ-8.1037-06132-10

• 2006-2007• #7 Wheel Hub: IMZ-8.1037-06020-10• #8 Front Brake Rotor: IMZ-8.1037-06026

(Not Available - Upgrade to Brembo item 8A and 8B)• #8A Front brake rotor IMZ-8.1037-06026-10

(from 2007 (Brembo))• #8B Brembo Brake Adapter IMZ-8.1037-06132

(Used to mount Brembo Rotor)• #20 Screw M8x16 200299-P27C

Ural Hydraulic Disc Brakes(Уральский гидравлические дисковые тормоза)

•Hydraulic Disk Brakes–Master Cylinder, Located on Right Side of Steering Handlebar–Hydraulic Fluid Hose, Connecting the Master Cylinder to the Brake Caliper–Brake Disk, Bolted on the Front Wheel Hub

RightRight--Hand Brake LeverHand Brake LeverCaliper Piston (Cup)Caliper Piston (Cup)

Hydraulic Brake LineHydraulic Brake Line

Front Brake Master Brake Cylinder (BMC): Front Brake Master Brake Cylinder (BMC): Brembo Brembo Model PS13 (10.4620.79)Model PS13 (10.4620.79)(www.(www.oppracingoppracing.com).com)

Lever to Master Cylinder

Fluid Reservoir

Brake Lever

Brake Hose Banjo Fitting

(Coupling Bolt)

ReservoirFluid Level

Viewing WindowHandlebar Bracket

Brembo SKU #’s:Lever: 110.4372.13Lever Pin: 110.2798.50Clamp: 110.4372.13Cap: 110.4308.60Inlet: 110.2706.50Micro-Switch: 110.4418.13

The Brembo part number is stamped on the bottom of the master cylinder reservoir, where the final two numbers indicate the piston diameter.

Front Brake Light Switch Front Brake Light Switch (www.f2motorcycles.ltd.(www.f2motorcycles.ltd.ukuk))

•Brake Light Micro-Switch for Disc Brake–Ural 750’s Fitted with Brembo Disc Front Brake–Two Slightly Different Types•2003-2008–IMZ-8.1037-17048-2007 (Discontinued in favor of a pressure switch on a banjo fitting)–f2Motorcycles: F23307/TO 2007–Brembo Part #: 110.4418.14 (switch is soldered into the harness a couple of inches from the switch, so you'll be splicing into the harness)–Most Switch Vendors List Distance between Mounting Holes, the one that fits is 10 mm, center-to-center.–IMZ-8.1037-17048-EU: Brake Switch, Italian, for European Wire Harness 2007

•2009-201X –IMZ-8.1037-17048-2009–f2Motorcycles: F23307/AFTER 2007–Brembo Part #: 10.4671.61

•Brembo 110.4418.13•List Price: $12.43

BremboBrembo Front Brake MicroFront Brake Micro--SwitchSwitch (www.(www.oppracingoppracing.com).com)

Brembo Brembo Fixed CaliperFixed CaliperP4 30/34 F (P4 30/34 F (BremboBrembo Part #: 20.6800.10)Part #: 20.6800.10)

•Fixed Caliper: 6800 Series•Four Opposed Pistons (2 x 30mm + 2 x 34mm dia.)•Pads Supported by Two Pins•Material: Cast Aluminum Body

BremboBrembo Part #Part #’’s:s:Bleeder Screw: 105.3246.14Bleeder Screw: 105.3246.14Dust Cover: 105.1502.10Dust Cover: 105.1502.10Retainers: 105.4542.18Retainers: 105.4542.18Pin/Retainer: 120.3942.30Pin/Retainer: 120.3942.30Pad Spring: 120.2255.90Pad Spring: 120.2255.90

65 mm Mounting Distance65 mm Mounting Distance

Two PadTwo Pad--Retaining PinsRetaining Pins

34 mm 34 mm diadia. Piston. Piston

30 mm 30 mm diadia. Piston. Piston

Bleeder ValveBleeder ValveFront of MotorcycleFront of Motorcycle

Rear of MotorcycleRear of Motorcycle

17 mm Mounting Bolts17 mm Mounting Bolts

It Appears that Ural Mounts (LeftIt Appears that Ural Mounts (Left-- and Rightand Right--Hand) Disc Hand) Disc Direction backwards from Direction backwards from Brembo Brembo Recommendation??Recommendation??

Hydraulic Brake Caliper and Brake Hose Hydraulic Brake Caliper and Brake Hose (downloads.(downloads.imzimz--uralural.com).com)

•Caliper Parts:#1 Front Brake Caliper: Brembo 20.6800.10#4 Brake Hose Assy: AMP1165#12 Bolt М10-1,25-6q х40 201682-P27C 4 each#14 Adapter: IMZ-8.125-27228#18 Sealing Washer: 10284460 7 each#20 Washer 10L: 252156-Р27С 2 each

Banjo FittingBanjo Fitting(coupling Bolt)(coupling Bolt)

Disc Brake and Hydraulic Line InspectionDisc Brake and Hydraulic Line Inspection•Check Disc Brake Pads Every Service Interval–Disc Brakes Do Not Require Adjustment–Brake Pads Inspected by Removing Dust Shield from Top of Caliper and Check the Thickness of the Pads–Pads Replaced when Less than 1/8” of Pad Remaining on Either Pad

•Check Brake Hose Every Service Interval–Brake Hose Inspected for Leaks and Cracks along Length of Hose–WARNING: Never Use Any Aftermarket Brake Hose for Front Brake. Use Only Genuine Ural Brake Hoses. Could Result in Front Brake Failure and Void the Warranty.–Check Banjo Fittings on Either End

•2008: Steel-Braided Brake Hoses–Stainless Brake Line - BIG Difference! (sovietsteeds.com) Rougaroo–Far Superior to Rubber Flex Lines–Brake Is Way More Responsive–With Stainless, There Is No Sponginess At All

Early Rubber Brake Hose for Disc BrakeEarly Rubber Brake Hose for Disc Brake(www.(www.uralural--zentralezentrale.de.de))

•Product No.: S2073-S•Manufacturer: SASIC FRANCE•Length: 96 cm•Pressed-on 10 mm Banjo Fittings with Protecting Tube•List Price: 11.89 EUR

Later SteelLater Steel--Braided Brake Line Braided Brake Line (www.(www.sovietsteedssovietsteeds.com).com)

Banjo FittingsBanjo Fittings

A Banjo fitting comprises a perforated hollow bolt and spherical union for fluid transfer, commonly found in automotive fuel, oil and hydraulic brake systems. The name stems from the shape of the fitting, having a large circular section

connected to a thinner pipe, generally similar to the shape of a banjo.

Brake Reservoir Brake Reservoir (Service Manual)(Service Manual)•Check Brake Reservoir Every Service Interval–try to get the master cylinder as level as possible (you might want to do this before you remove the cover)–Wipe off all dirt and avoid any contamination of the brake fluid in the reservoir–remove the two top screws on the reservoir–Remove the cover and the rubber gasket–Fill the reservoir to within 1/4 inch of the top with only DOT approved 3 or 4 brake fluid–Be careful not to spill brake fluid on the paint, as damage to the paint may occur–Squeeze the brake lever several times to ensure that any air that has been introduced is forced out of the system.–Replace Rubber Gasket, Cover and Two Screws

•Bleeding the Brake Line after the hose has been replaced–Remove Cover as Above–squeeze the brake handle while at the same time, open the bleeder on the brake caliper. –When the lever goes all the way in, close the bleeder, release the lever and do it again (and again, etc) until you get no more air bubbles from the bleeder.–Don't let your master cylinder run low or you'll have to start from scratch. You may want a helper!

Brake Fluid: DOT 3, 4 and 5 Brake Fluid: DOT 3, 4 and 5 (www.(www.cyclebrakescyclebrakes.com).com)

•All Brembo Braking Products Use Natural, Rubber-Base Seals–USE ONLY DOT-3/4 NON-SILICONE Type Fluids such as CASTROLTM 'LMA' –INCOMPATIBLE with DOT-5 Silicone-Based Brake Fluids–DOT- 5 SILICONE-based Fluids React with Natural-Rubber Seals to Swell Them•CAN CAUSE SEVERE PISTON RETRACTION PROBLEMS•No cure for problems caused by DOT-5, other than complete seal replacement

•The cap on the rectangular master cylinders says "DOT 3 - 5 Fluids“–Silicone DOT- 5 fluids are NOT generally in use in Europe, but Glycol-based "DOT-5.1" fluids ARE.–Hence, the "DOT-5" cap designation

•For best braking performance, we recommend changing brake fluid twice a year. If the machine is to be stored in a damp environment (over the winter, say), we recommend installing fresh fluid before and after the storage period. At minimum service levels, glycol brake fluids MUST be completely changed at intervals not to exceed a period of 18 months. •DOT-4 has a higher boiling point than #3–Probably only an issue when REALLY heating up the brakes–DOT-3 will get it done fine on a Ural

•Dot 3 will slowly attack British brake rubber•Dot 4 is compatible with British brake rubber parts•Dot 5 is silicone brake fluid

EBC DoubleEBC Double--H Sintered Metal Brake Pads: FA244HHH Sintered Metal Brake Pads: FA244HH•Folks Start Replacing Pads between 10 and 15 kms•Brake Friction Surfaces (disc rotor) Should Be Good for Life of the Motorcycle and/or Owner, whichever comes first.• IMZ's Part Number for Brake Pad Set: IMZ-8.1238-27097•Less Expensive, Fully-Reliant EBC Replacement is FA244HHFA244HH–HH Rated: Highest friction rating •Double-H Became Standard by Which All Brake Pads Are Judged•Double-H pads claimed their name from the industry standard gauge for measuring friction levels on brake pads•Grades of brake pads range from E,F,G through to H rating, each grade being a 20% step up in friction delivery

–Double H: H rated cold and H rated when hot–Long-Lasting and Powerful Brake Effect, Do Not Fade–Fits Brembo 20.6800.10/20 4-piston (two-pin pad fixing) Calipers

Holes for Pad-Retaining Pins on Calipers

High-friction, Double-H sintered pads offer the maximum brake effect and a lifetime approximately double that of any organic pad.

EBC EBC Carbon Graphite (Organic) Brake Pads: FA244Organic) Brake Pads: FA244•Typical Organic "feel" which Many Riders Prefer • Ideal for general use with low rotor damage characteristics •Environmentally friendly, free of asbestos, lead and other toxic materials •Pads for Leisure / Sport Use · Lowest heat generation · Good for fast, dry, riding · Optimum 280 mm size Rotors•The EBC Kevlar series has now been renamed NAO series or Non-Asbestos Organic, although the famous DuPont Kevlar fiber is still used in conjunction with other high-tech fibers that have come on the market.

Replacing Front Disk Brake PadsReplacing Front Disk Brake Pads (www.sovietsteeds.com)• 2005 Patrol• Started to Hear Metal Squeal Sound and Feel Brake Fade.1. Drape an Old Towel under Front Brake Fluid Container or Master Cylinder by the

Handlebars, because Some Fluid Will Come Out2. Remove Two Small Cir-Clips with Needle-Nose Pliers, that are into the Holding

Pins (2) by Front Brake Pads. Holding Pins Have to Be Rotated until Cir-Clips Are Exposed from under the Side of the Dust Cover. At the End of the Holding Pins Is a Squared-Off End for a Place to Grab Them. Once Removed, Pull Out the Holding Pins. These Pins Go thru the Eyelets of the Brake Pads and thru the Brass-Looking Dust Cover on Top. (DO NOT TRY AND PRY THE BRASS DUST COVER OFF! You'll destroy it. That dust cover is held in place by the holding pins.) Make Note that the Dust Cover Has an Arrow On It. That Arrow Points towards the Bike/Engine, Looking at It from the Front of the Bike.

3. Remove Cover from Brake Fluid Master Cylinder. DO NOT PUMP THE FRONT BRAKE LEVER WITH THE MASTER CYLINDER COVER OFF! Or You Will Get a Fountain of Brake Fluid all over.

4. Remove Old Brake Pads

Replacing Front Disk Brake PadsReplacing Front Disk Brake Pads (www.sovietsteeds.com)5. Look Down at Four Pucks that Engage the

Pads. If Pads Are Shot, the Pucks Are in Towards the Brake Rotor pretty good.

6. Take Expander Tool (Harbor Freight for $7), Primarily Used for Removal of Rubber Hoses, but Works Great for Spreading Out the Pucks. When Pucks Are Expanded, the Fluid in the Master Cylinder Starts to Rise. Some Fluid Will Overflow. Because the New Pads Are Thick, They Require that the Pucks Are Spread Out or Re-Tracked as Much as Possible to Fit In the New Pads.

7. Once Pucks Are Spread, Put In the New Pads. To Get the Eyelets (2 on each pad) to Line-Up with the Brake Pad Mounts for the Holding Pins to Go Back In, Use a Small Ice-Pick to Go thru the Brake Mount Hole on the the In-Board Side of the Mount, Hold Up the New Brake Pad on the In-Board Side, Put the Dust Cover Back in Place over the Pads and Rotor, and Put Back in the Holding Pins.

8. Once the two holding pins are in which go through the two new pads and through the dust cover, I put back in the two retaining cir clips. One for each holding pins. Then I turned the holding pins to hide the top of the cir clips under the brass dust cover. Shot after 15,000 km's

Replacing Front Disk Brake PadsReplacing Front Disk Brake Pads (www.(www.sovietsteedssovietsteeds.com) .com) cont.cont.9. Once all assembled, I put the master cylinder cover back on. Then I pumped the

front brake lever till I felt it regain action. Then I took the master cylinder cover back off and put a little Dot 4 brake fluid (On newer Urals, older Urals I believe use Dot 3) to make up for lost fluid. Put the Master cylinder cover back on. Then I took her for a spin in my neighborhood and tested several times. According toBrembo instructions, the pads should be run in for about 25 mikes or so, meaning that I should go easy on them, but confidently use them till they burnish in. When I first went around the block, I made several stops and went back home, the rotor was very hot to the touch. But after another ride of about 2 miles they were not as hot, so the new pads are sitting right against the rotor when new. As I run her she should settle out.

10. Another thing I do is when the pucks are out, I spray em with WD40 and scrub off the grime with a soft bristle toothbrush. Rinse with brake-clean, and re-hydrate the rubber seals with a protectant.

The tool is for rubber hose removal but works great for spreading brake pucks.

ReRe--Build of Brake Master Cylinder (BMC) on 2007 PatrolBuild of Brake Master Cylinder (BMC) on 2007 Patrolby URAL CT, Plano, TX by URAL CT, Plano, TX ((sovietsteedssovietsteeds.com.com))

•Brembo Kit for Brake Master Cylinder: SKU or part number of kit from Yoyodyne: 110.4362.50 cost: $18.27 (http://www.yoyodyneti.com/ProductInfo.aspx?productid=110.4362.50)

BMC re-build kit on left and master cylinder to the right. All the component needed plus the

lubricant that came with the kit. Note the O-ring, seal (white), & seal retaining ring (silver)...these go into the BMC bore.

ReRe--Build ofBuild of BremboBrembo Brake Master Cylinder on 2007 PatrolBrake Master Cylinder on 2007 Patrolby URAL CT, Plano, TX by URAL CT, Plano, TX ((sovietsteedssovietsteeds.com.com) cont.) cont.

1. Remove all fasteners securing the brake hose to the rig2. Drain all the brake fluid out, including the caliper3. Loosen banjo bolts4. Detached the Brake Master Cylinder (BMC) from the handle bar. Since I will be rebuilding

the caliper, I loosened the caliper banjo bolt too, then I removed the whole front disc brake system.

5. Separate BMC and Caliper from Brake Hose (make sure you do not loose copper washers). Now you may proceed to work on it from a workbench.

6. Take the brake lever out and set it aside.7. Remove the pin, dust cover, & plunger assembly. All you have left in the BMC cavity are

the seal retaining ring, seal and O-ring.

Remove nut and pin to separate Remove nut and pin to separate lever from BMClever from BMC

New parts on left and used parts New parts on left and used parts on right. Seal retaining ring, on right. Seal retaining ring, seal, & oseal, & o--ring still in BMCring still in BMC

8. Carefully remove (pry with a small screw driver or dental pick) the seal and retaining ring. Then you’ll have clear access to remove the O-ring.

9. Clean the BMC using your favorite brake cleaner.10. Check the bore to make sure it is not damaged, gouged, or pitted. Use an ultra

fine sandpaper and gently remove any burrs you may have left from the disassembly. Clean it again (repeat #9).

11. Using the Brembo provided lubricant, carefully assemble the items in the kit to the BMC .…O-ring, the seal, then the seal retaining ring. Find a suitable drift to install the retaining ring carefully.

ReRe--Build ofBuild of BremboBrembo Brake Master Cylinder (BMC) on 2007 PatrolBrake Master Cylinder (BMC) on 2007 Patrolby URAL CT, Plano, TXby URAL CT, Plano, TX ((sovietsteedssovietsteeds.com.com) cont.) cont.

Items still in the BMC. You have to Items still in the BMC. You have to carefully remove these parts out. DO carefully remove these parts out. DO NOT DAMAGE the bore of the BMC.

Should look like this when installed.Should look like this when installed.NOT DAMAGE the bore of the BMC.

•…Assemble the spring & stop, install the brass washer onto the piston (akaplunger), the small rubber seal, then the spring/stop assembly.…Carefully insert lubricated piston assembly into the bore.…Place the dust seal and using the plunger pin, carefully install the lever/bolt and use the lever to push in & hold the assembly in place while you work the dust seal around to install it. Tricky operation but you’ll get it.12. Install the BMC to the handle bar. If all you’re rebuilding is the BMC, put in your brake fluid of choice (DOT3 or 4) and bleed the brake system. Didn’t put in the brake fluid yet because I was going to rebuild the caliper too. My preference is DOT4 because I think it’s less hydroscopic than DOT3.

ReRe--Build ofBuild of BremboBrembo Brake Master Cylinder (BMC) on 2007 PatrolBrake Master Cylinder (BMC) on 2007 Patrolby URAL CT, Plano, TXby URAL CT, Plano, TX ((sovietsteedssovietsteeds.com.com) cont.) cont.

The The damageddamaged plunger seal on myplunger seal on my Ural's Ural's BMC. That was BMC. That was the reason why the BMC could not build pressure to the reason why the BMC could not build pressure to activate the caliper pistons. I think the piece is lodged activate the caliper pistons. I think the piece is lodged inside the brake hose and blocks the fluid from inside the brake hose and blocks the fluid from releasing the pistons causing the front brake to "hang releasing the pistons causing the front brake to "hang up". Note: I'm just showing the damaged seal...cup side up". Note: I'm just showing the damaged seal...cup side of seal should be facing towards the banjo end of BMC

Notice the clipped piece Notice the clipped piece from the seal...from the seal...

of seal should be facing towards the banjo end of BMC

Seal Repair Kit for Brembo Caliper on 2007 Patrolon 2007 Patrolby URAL CT, Plano, TX by URAL CT, Plano, TX ((sovietsteedssovietsteeds.com.com) )

• Seal Repair Kit from Yoyodyne: YB3034 ~$501. Drain All Brake Fluid from Brake master Cylinder (BMC) and Caliper (you need

to change the fluid anyways)2. Remove Caliper from the Rig. Do Not Remove the Hose Attachment from the

BMC End, unless you're Re-Building the Master Cylinder too.3. With Caliper Out, Place It on Work bench, Remove the Brake Pads. Use the Ural

Air-Pump with the Pointed Attachment that Came with the Pump. Place a piece of corrugated cardboard between the brake pistons and give the handle a swift pump. The pistons will come out but they may or may not pop out completely. The cardboard will prevent the pistons from banging against each other. You can also use rags. You can use compressed air but dial the air pressure way down so the pistons do not come flying out. Watch out because there may be some residual fluid in the bore.

Close up...notice the UralClose up...notice the Ural--supplied supplied pointed attachmentpointed attachmentUral air pump attached to the caliperUral air pump attached to the caliper

Seal Repair Kit for Brembo Caliper on 2007 Patrolon 2007 Patrolby URAL CT, Plano, TX by URAL CT, Plano, TX ((sovietsteedssovietsteeds.com.com) cont.) cont.

4. Using a #40 torx bit, Remove the 4 Bolts that Attaches the Two Halves Together. Again Take Care not to ding the pistons or mating surface.

5. Carefully separate the two halves and remove the pistons...again take care in removing them.

#40#40 TorxTorx bitbit

Note the 4 bolts securing theNote the 4 bolts securing the BremboBrembocaliper halves Two of the pistons...there are four Two of the pistons...there are four

(2) 30mm & (2) 34mm pistons(2) 30mm & (2) 34mm pistonscaliper halves

6. Remove one O-ring and the old seals from the caliper using a dental pick or any suitable tool. Do not damage the bore. Replace them with the new seals, two per bore. Pay attention to the size, one bore is 30 mm & the other is 34 mm.

7. Wet the pistons with brake fluid and carefully align a piston to the proper bore and push in to seat. Alignment is critical for ease of installation.

8. Assembly of the two halves is the reverse. Securely tighten all 4 bolts. Install caliper to the rig. BTW, I used this pin set to clear the small openings from the brake master cylinder. There are 2 small holes on the reservoir.

Seal Repair Kit for Brembo Caliper on 2007 Patrolon 2007 Patrolby URAL CT, Plano, TX by URAL CT, Plano, TX ((sovietsteedssovietsteeds.com.com) cont.) cont.

Here's a pix of the set Here's a pix of the set of new seals and an of new seals and an

OO--ring. Wet them ring. Wet them with brake fluid with brake fluid

before installationbefore installation

Note that the bottom seal is thicker Note that the bottom seal is thicker than the top (wiper) seal.

Pin set used to clean the Pin set used to clean the small openings in thesmall openings in the carbcarb

too.too.than the top (wiper) seal.

Repair Kit has 4 pistons (2) 30mm & (2) 34mm, 4 seals, 4 scraper seals, & 1 O-ring.

BremboBrembo--Recommended Brake Bleeding Procedures Recommended Brake Bleeding Procedures (www.(www.cyclebrakescyclebrakes.com).com)

1.Fill the master cylinder reservoir with fresh, specified brake fluid from a sealed container. Operate the master cylinder lever SLOWLY several times to fill the brake circuits and begin to expel air from them.

2.Connect a transparent plastic tube (of appropriate bore for a leakproof fit) to the caliper bleed valve, placing the free end in a brake-fluid-proof container. Position the bleed tube so that it rises above the bleed valve for a few inches (to allow a fluid head above the bleed valve exit) before descending into the container.

3.Operate the brake lever 3 - 4 times, keeping it pulled in on the last stroke. Loosen the caliper bleed valve enough to allow fluid and purged air (seen as bubbles in the fluid) to enter the attached tube. Close the bleed valve. Repeat this operation several times while maintaining a sufficient fluid level in the master cylinder reservoir. With each cycle of bleeding, the lever should meet with more resistance, indicating that the air is being removed from the system (there should also be progressively fewer bubbles in the purged fluid in the tube). If conditions are ideal, satisfactory lever resistance should be attained at the point no more bubbles are observable in the purged fluid in the tube.

4.Occasionally, a system will still have "spongy" lever even though no more air can be found in the purged fluid. This indicates air is still trapped in some part or parts of the circuit, and must be removed. The following methods will help to free the trapped air and complete the bleeding process: (a) Making sure the reservoir is filled and capped, lean the machine so the reservoir is positioned above the master cylinder outlet, then give the lever several short, quick strokes. This gives the residual air a less- interrupted upwards path towards the reservoir, and out of the line. Return the machine to the upright position, rap the calipers sharply with a plastic hammer or screwdriver handle, manipulate the flex lines and repeat. If this doesn't quite correct the problem, let the machine sit overnight and repeat the next day. In most cases, this should give an air-free final bleed. Be sure the reservoir is filled to the correct level after final bleeding. (b) In the case of master cylinders mounted on clip-on bars with a steep angle, it may be difficult to lean the machine sufficiently to position the reservoir above the master cylinder outlet. In this case it will be necessary to bleed the fitting at the high point (i.e. the master cylinder outlet).

Bleeding Bleeding BremboBrembo Brake System Brake System ((Brembo Brembo Brake Catalog)Brake Catalog)http://www.http://www.cyclebrakescyclebrakes.com/.com/BremboBrembo_catalog._catalog.pdfpdf

•To bleed the brakes proceed as follows:–Turn the handlebar until the top edge of the reservoir is horizontal.–Fill the reservoir with brake fluid ;•During bleeding avoid letting the brake fluid level go below the MIN level.

–Apply the brakes several times to fill the braking system partially.–Insert a flexible transparent tube to the bleed screw.–Bleed through one bleed screw at a time:•Pull the brake lever all the way and keep it in this position;•Unscrew the bleed screw, let some brake fluid flow out (initially only air will come out) and then tighten the bleed screw (lightly);•Let go of the brake lever, wait a few seconds and repeat the above steps until no air bubbles come out of the bleed screw;

–Tighten the bleed screw to the prescribed torque and fill up the reservoir with brake fluid.–Verify that there are no leaks from the various fittings and connections. If the braking system has been bled properly, following the lever dead travel, you will feel the direct action of the fluid without any sponginess; if this is not so, repeat the bleeding procedure.

•Notes: If the lever seems too elastic following the bleeding procedure, proceed in the following manner:–Remove one brake pad from a caliper.–Apply the brakes several times so as to push-out the pistons about 3 - 4 mm.–Push back the pistons (avoid damaging the rotor and the pistons).–Put the brake pad back into the caliper.–Repeat the above steps on the other(s) pad(s) and/or caliper(s).–Verify whether brake lever travel has improved.

Ural (Ural (УралУрал) ) 20012001--20042004

The front brake-light switch is placed in parallel with the rear brake-light switch.

2010 Ural Schematic2010 Ural Schematic

The front brake-light switch remains the same over the years.

Disk Brake System Disk Brake System (www.(www.uralural--zentralezentrale.de).de)•Product #: S2073•List Price: 275 EUR•Disk brake conversion kit for all models•Brake disc is simple plugged in the wheel splines•Delivered with brake disk with flange, mounting and cover, brake calliperwith brake pads, hydraulic hoses with fittings, master cylinder with lever and bolts.•Caution: Caliper bracket has to be welded on the fork or swing-arm. Suitable only for experienced DIY mechanics!

Disc Brake Conversion for Disc Brake Conversion for DneprDnepr FrontFront WheelWheel::Christian's Christian's Dneprseiten Dneprseiten ((dneprdnepr.at/e/tech_26..at/e/tech_26.htmhtm))

•Dnepr Front Drum Brake Not Made for Panic Braking•The Conversion : –Front Wheel Yamaha SR500 (also possible: XS650) –Two Brake Discs SR500 diameter = 298mm (or XS1100) –Brake Pliers and Pump Yamaha XS850 (identically XS1100)–Steel-Flex Hose without Distributors Directly to the Pump –Taper Roller Bearing for the Steering –Bearings at the Front Wheel Were Changed to 20mm inner diameter, an Appropriate

Spacer Was Made–Disc Brake Lugs Made of Steel Plates (5mm) on Roller Bearings Situated on the Axle

Dual Front Wheel DiscsDual Front Wheel Discs

Dual Hydraulic Brake LinesDual Hydraulic Brake Lines

Fluid ReservoirFluid Reservoir

ThreeThree--Wheel Disc Brake ConversionWheel Disc Brake Conversion ((dneprdnepr.at/e/.at/e/gaga__monegamonega..htmhtm))•Based on Dnepr•Disc Brakes on All Three Wheels (Brembo d'Or – Gold Brembo)–Quick-Locking Mechanisms for Hydraulics–Adapters from Full Aluminum, etc.

•Foot Brake Pedal Operates the Side Car - and Rear Wheel AND a Small Caliper behind the front caliper•Real Integral Brake Assembly with Full Exchangeability of Wheels

russian motorcycles brembo disc brake systemsup.picr.de/18504456bf.pdf · russian motorcycles...

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