Kickstarter on motorcycles Ural - a unit that takes on colossal loads every time the engine starts. Over time, even the most reliable design wears out: there is play, a crackling sound when pressed, or the pedal completely falls without resistance. If your kickstarter stopped working, do not rush to take your motorcycle to a service center - most of the faults can be fixed on your own if you have basic tools and patience.

In this article we will look at all stages of repair: from diagnosing a breakdown to assembling the mechanism, taking into account typical errors. We will pay special attention unique “diseases” of Ural kickstarters associated with the design of the gearbox and the peculiarities of Soviet engineering. You will learn how to replace worn dogs, adjust the spring, and why sometimes the problem lies not in the starter itself, but in the gearbox.

The material is suitable for owners of all modern models: Ural Gear-Up, Ural Retro, Ural Solo, as well as classic M-62, M-66 and their modifications. Let's get started!

Signs of a broken kickstarter: when repairs are needed

The first signal about problems with kickstarter - change in pressing force. Normally, the pedal should be compressed smoothly with uniform resistance, and after starting the engine, it should clearly return to its original position. If you notice at least one of these symptoms, the mechanism requires attention:

  • 🔧 The pedal falls without a click or “crunch” - a sign of wear dogs or a broken return spring.
  • 🔊 A metal grinding or crackling noise when pressed is a signal that the teeth on the drive gear or overrunning clutch.
  • 🔄 The pedal does not return to the top position - there is a problem with the spring or the axle is jammed.
  • 💥 A sharp blow to the leg during startup - a spring break or lever deformation is possible.

On motorcycles Ural with cardan drive (For example, Gear-Up) a faulty kickstarter may manifest itself differently: the pedal may “stick” in the lower position due to shaft misalignment or bearing wear. It is also worth checking whether the problems are related to locking mechanism — on some models it is triggered when the gear is engaged, blocking the starter.

⚠️ Attention! If the kickstarter is stuck in the pressed position, do not try to start the engine - this can lead to destruction of the gearbox gears. First, disassemble the mechanism and eliminate the cause.
📊 How often do you use kickstarter in the Urals?
  • For launch only
  • Often (daily)
  • Rarely (once a week)
  • I hardly use it

Tools and spare parts for Ural kickstarter repair

To disassemble and repair a kickstarter, you will need a standard set of tools, but there are also specific tools. Here's the full list:

Tool/spare part Purpose Note
17 mm wrench Unscrewing the kickstarter axle nut It is better to use a cap or end
Slotted screwdriver Removing the retaining rings and mechanism cover Preferably with a magnetic tip
Pliers or round nose pliers Installing/removing retaining rings Pliers won't work - you'll bend the rings
Hammer and drift Knocking out an axle or gears Use a copper or aluminum drift
Torque wrench Tightening the axle nut to the correct torque Tightening torque - 4–5 kgf m

The most commonly required spare parts are:

  • 🔄 Kickstarter dogs (set of 2-3 pieces) - wear out the fastest.
  • 🔧 Return spring - breaks or loses elasticity.
  • ⚙️ Drive gear (if the teeth are chipped or worn).
  • 🛠️ Kickstarter axle seal — if oil leaks are noticed.
  • 🧲 Retaining rings (it’s better to take extra - they often break when removed).

For motorcycles Ural after 2010 release (for example, Retro or Solo) spare parts from IMZ-8.103 or IMZ-8.107. For older models (M-62, M-66) look for parts with markings IMZ-6.103. Please note: dogs The engagement angle may differ depending on the model!

💡

Before purchasing spare parts, remove the kickstarter cover and check the markings on the gears - this will help avoid selection errors.

Step-by-step disassembly of the kickstarter: from the pedal to the freewheel

We begin disassembly by removing the pedal and mechanism cover. Important! Before starting work, make sure that the motorcycle is standing on central stand or securely fixed - this will prevent falling when force is applied.

  1. Remove rubber cover from the kickstarter pedal (it is secured with rivets or screws).

  2. Unscrew axle nut wrench 17 mm. If the nut is stuck, use a penetrating lubricant (for example, WD-40) and leave for 10–15 minutes.

  3. Remove lock washer and carefully pull out the axle along with the pedal. Be careful - the spring inside may fall out!

  4. Unscrew the 4 mounting bolts kickstarter caps (10 mm wrench) and remove it. Under the cover you will see a mechanism with dogs and gears.

Now you need to extract overrunning clutch (aka Bendix). To do this:

  1. Secure the gearbox housing in a vice using soft spacers (for example, wooden blocks).

  2. Using a hammer and drift, carefully knock out drive gear kickstarter. Apply blows strictly along the axis so as not to damage the teeth!

  3. After removing the gear you will see dogs and their springs. Usually they fall out on their own - collect them in a separate container so as not to lose them.

Wear of teeth on the drive gear|Condition of the pawls (chips, wear)|Integrity of the return spring|Kickstarter axis play|Presence of metal shavings in the oil-->

At this stage, carefully inspect all the details:

  • 🔍 Dogs must have sharp edges without chips. If they are “licked”, they need to be replaced.
  • 🔗 Pawl springs must not be stretched or deformed.
  • ⚙️ Gear teeth - if wear exceeds 30%, replacement is required.
  • 🛢️ Oil in housing - if it is black or with metal shavings, washing is necessary.
⚠️ Attention! On motorcycles Ural with stroller (For example, Gear-Up) when disassembling the kickstarter, additional removal may be required cardan shaft, as it interferes with access to the gearbox cover. Don't forget to mark the relative positions of the parts with a marker!

Diagnostics and replacement of worn parts

The most vulnerable elements of a kickstarter are: dogs And return spring. Their wear occurs due to constant impact loads. Let's look at how to identify a malfunction and what to do in each case.

1. Worn or broken pawls

The pawls (aka “crackers”) are responsible for engaging the kickstarter gear with crown of the flywheel. When they wear out, they slip and the starter does not turn the engine. Signs:

  • 🔊 Characteristic crackling sound when pressing the pedal.
  • 🔄 The pedal falls without resistance.
  • 🔧 Visible chips or “licked” edges on the dogs.

To replace:

  1. Remove the old pawls and their springs from the grooves.

  2. Install new parts after lubricating them motor oil (For example, Lukoil 15W-40).

  3. Check that the pawls move freely in the grooves but do not fall out.

2. Broken or stretched return spring

If the pedal does not return to the up position, the spring is to blame. On Urals it is located inside the kickstarter axis. Signs:

  • 🔄 The pedal remains in the lower position after starting.
  • 💥 A sharp blow to the leg when returning (if the spring is torn).

Spring replacement:

  1. Remove the kickstarter shaft and remove the remains of the old spring.

  2. Install a new spring by first compressing it and fixing the ends in the grooves of the axle.

  3. Check the operation: the pedal should return smoothly, without jamming.

3. Worn gear or overrunning clutch

If you hear when you press the pedal metallic grinding, the problem may be in the gear or clutch. Inspect:

  • ⚙️ Drive gear - the teeth should not be beveled or chipped.
  • 🔄 Overrunning clutch - it should only rotate in one direction.

If there is severe wear, the gear or clutch will have to be replaced. On Urals these parts often come complete with the shaft, so sometimes it’s easier to buy kickstarter kit (article IMZ-8.103-1701010 for modern models).

How to check the overrunning clutch without disassembling?

Turn the kickstarter pedal in both directions by hand. In good condition, it should only rotate clockwise (when viewed from the pedal side). If the pedal spins in both directions or sticks, the clutch is faulty.

Kickstarter assembly: errors and nuances

Assembling the mechanism requires care - one incorrectly installed part can lead to repeated failure. Follow this algorithm:

  1. Install overrunning clutch on the gearbox shaft. It should fit all the way without distortion.

  2. Put it on drive gear and secure it with a locking ring. Check that the teeth line up with the slots on the coupling.

  3. Lay down dogs into the grooves, having previously lubricated them. They should “look” with their sharp edges in the direction of rotation of the gear.

  4. Install pawl springs - they should press the crackers against the gear.

  5. Close the mechanism with the lid and tighten the bolts crosswise (torque - 1.5–2 kgf m).

  6. Insert the axle with the pedal, put on the lock washer and tighten the nut (torque - 4–5 kgf m).

Pay special attention to two points:

  1. Pawl position. If they are turned over, the kickstarter will slip. On Urals correct position - when beveled edge directed in the direction of rotation gears.

  2. Tightening the axle nut. An undertightened nut will lead to play and accelerated wear, and an overtightened nut will lead to jamming of the mechanism.

⚠️ Attention! After assembly, check the kickstarter operation without starting the engine. Press the pedal several times: it should return smoothly to the top position without jamming. If you hear a grinding noise, disassemble the mechanism and check the installation of the pawls.
💡

The most common assembly mistake is incorrect installation of the retaining ring on the drive gear. If it is not completely seated in the groove, the gear will play and wear out quickly.

Kickstarter adjustment after repair

Even after proper assembly, the kickstarter may not work perfectly. Most often required pedal travel adjustment or eliminating backlash. Here's how to do it:

1. Free play adjustment

The free play of the pedal (until the pawls are activated) should be 10–15 mm. If it is larger or smaller, adjust it:

  1. Loosen the kickstarter axle nut.

  2. Turn the axle clockwise to reduce free movement, or against - to increase.

  3. Tighten the nut and check the pedal travel.

2. Elimination of backlash

Play in the pedal usually appears due to wear axle bushings or loosening of fastening. To fix it:

  • 🔧 Tighten the axle nut (but do not overtighten!).
  • 🛠️ Replace worn bushings (part no. IMZ-8.103-1701020).
  • 🔗 Check the fastening of the kickstarter cover - the bolts may have become loose.

3. Trigger check

After adjustment, check the kickstarter in operation:

  1. Turn off the ignition and press the pedal several times - it should return smoothly.

  2. Turn on the ignition and try to start the engine. If the starter slips, check the installation of the pawls.

On motorcycles Ural with electric starter (For example, Retro) may be required after repairing the kickstarter mechanism synchronization. To do this:

  1. Start the engine using the electric starter.

  2. Press the kickstarter pedal 2-3 times - this will help “seat” the dogs.

Typical problems after repair and their solutions

Even if you did everything according to the instructions, problems may arise after the repair. Let's look at the most common ones and how to eliminate them.

Problem Possible reason Solution
Pedal doesn't return The return spring is torn or incorrectly installed Disassemble the mechanism, check the spring
Crackling sound when pressed Pawls installed on the wrong side or worn out Turn over the pawls or replace them
The pedal is stuck The axle nut is overtightened or the mechanism is dirty Loosen the nut, wash the parts with kerosene
The starter does not crank the engine Pawls are slipping or gear is worn Replace pawls or gear, check flywheel clutch

If after repair the kickstarter still does not work, check:

  • 🔧 Clutch of pawls with flywheel crown — the teeth on the flywheel may be worn out.
  • 🔄 Gearbox shaft play - if there is one, the box will need to be repaired.
  • 🛢️ Transmission oil level - its deficiency accelerates the wear of parts.
⚠️ Attention! On motorcycles Ural with kickstarter blocking (For example, Gear-Up 2015+) check the operation of the blocker. If it is stuck, the pedal will not return even after replacing the spring. The lock is located next to the gear shift mechanism.

Prevention: how to extend the life of a kickstarter

To avoid frequent repairs, follow these recommendations:

  • 🛢️ Change the gearbox oil every 10,000 km. Use gear oil TAD-17I or Lukoil TM-5 85W-90.
  • 🔧 Adjust free play pedal once a season - this will reduce the load on the dogs.
  • 🚫 Don't press the pedal when the engine is running, this destroys the mechanism.
  • 🔊 Watch out for extraneous sounds. At the first sign of a crack, disassemble the kickstarter - early repairs are cheaper.
  • 🛠️ Lubricate the pedal axle through the grease nipple (if equipped) every 5,000 km.

On motorcycles Ural with stroller The load on the kickstarter is higher due to the increased mass. In this case:

  • 🔧 Install reinforced pawls (for example, from IMZ-8.107).
  • 🛢️ Use oil with increased extreme pressure properties (for example, Castrol Syntrax Universal Plus).
💡

The most common cause of kickstarter failure in the Urals is untimely oil change in the gearbox. Metal shavings and dirt accelerate the wear of pawls and gears by 3-4 times!

FAQ: Frequently asked questions about Ural kickstarter repair

Is it possible to repair a kickstarter without removing the transmission?

Yes, on most models Ural The kickstarter cover can be removed without dismantling the box. However, to replace the overrunning clutch or drive gear, the gearbox will still have to be removed.

What is the resource for Kickstarter dogs?

During normal use, the pawls serve 30–50 thousand km. On motorcycles with a sidecar or during aggressive starting, the resource is reduced to 20 thousand km.

What is the difference between the Ural Gear-Up and Ural Retro kickstarters?

The main difference is in the design overrunning clutch. On Gear-Up it is more massive and designed for increased loads. May also differ pawl springs (on Retro they are softer). Spare parts are not always interchangeable!

Is it possible to start a motorcycle with a faulty kickstarter?

If the kickstarter slips or sticks, start the motorcycle not recommended - this can damage the gearbox gears. As a last resort, use electric starter (if there is one) or push start.

Where to buy spare parts for the Ural kickstarter?

Original spare parts can be ordered from official dealers IMZ or in stores:

For older models (M-62, M-66) parts are often found at disassembly sites.