Professional Documents
Culture Documents
Electric Starters
for
Russian Motorcycles
Part XI: Electric Starter
Evolution
Ernie Franke
eafranke@tampabay.rr.com
09 / 2017
Electric 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
2
Ural Starter / Generator / Alternator Timeline
Roughly
35-Amp 55-Amp Nippon Denso
Wattage = 14 Volts X Amps Alternator
Russian Alternator
14.3771 (Hand Grenade) (770-W, metal rear cap)
Kick-Start Only 18-Amp (500 W, black-plastic rear cap) (Longer by 20 mm)
Hitachi
14 Amp Starter-
Gen/ Russian-Built Generator Voltage Regulator
Г-424 (G-424) internal to Alternator
Alt (200-W)
Alternator Factory Electric-Start Added
(150-Watt)
New Transmission Case New Engine Design
Electric-Start (Flywheel Starter Added, (Alternator on top / Flywheel Starter
(E-Start) Option & Retro- New Wiring Harness) placed on bottom)
Engine fit introduced by CSMI
650 cc 750 cc Engine
Size
Factory Electric-Start
(E-Start) Offered New Wiring Harness
(Starter at Flywheel, Two Relays (Electrona in Austria)
Start Alternator on Top Center) One Relay One Relay
Relays
(RY-115) Ducati
No Points-Ignition Urals
Type V
Approved for U.S. sale
Type IV
Ignition Type II Type III Ignition (Type IV with
electronics moved
Type Type I into airstream)
1994 ‘95 ‘96 ‘97 ‘98 ‘99 2000 ‘01 ‘02 ‘03 ‘04 ‘05 ‘06 ‘07
Ural imported to U.S. by CSMI (Classic 1998.5 Year 3
Motorcycles and Sidecars, Inc.)
750cc Breakdown Showing Electric Starter
Gearbox
Foot Gear-Shift Lever
Kick-Start Lever
Branch Couplings
Г-424 Generator
5
Prior to 1998, Urals only had foot kick-start.
Post-1998.5 / Pre-2003 Ural 650’s with Electric-Start
2000 Ural Bavarian Classic 2000 Ural Patrol (650 cc)
(650cc)
6
After 1998, Urals only had optional electric-start for their 650’s.
Post-2003 Ural 750’s with Electric-Start
2013 Gear-Up
7
With the conversion to 750cc in 2003, electric-start was standard.
Ural Starter-Motor 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
9
The CT369 starter engages the flywheel of the Vortex 30 Hp outboard engine.
Original 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. Body
2. Pole with Field Coils
3. Drive Cover
4. Commutator Cover
5. Motor Anchor (Rotor or Armature)
6. Ring Type Collector (Commutator)
7. Drive Gear
8. Traction Relay
9. Relay Anchor (Armature)
10. Lever
11. Rod or Stem
12. Movable Contact
13. Terminal
14. Terminal Lug
15. Return Spring
16. Return Spring
The CT369 solenoid pulls the lever (10), which engages the 10
starter drive gear (7) into the motorcycle’s flywheel gear.
Ural Electric Starter
Inscription: IMZ-8.124-18075-10
Inscription: 320.3708
11
The earliest CT369 was the shorter electric starter for Urals.
Old & New (Longer) CT369 Diagram (www.electromash.com.ua)
The End-Cap of the Later Version (CT369Б) Extends about 25mm
Beyond the Electrical Terminals. On the Earlier Version (CT369),
the Terminals Are Nearly Flush (10mm) with the End-Cap.
Ф80mm
157.5mm
172.5mm
1111-3708800: Starter
Solenoid for
VAZ-1111 Starter
Ignition
Switch
KMZ CT362A
Fits: Dnepr, Ural
Item: CT362A
List Price: $109.95
(dnepr-kiev.com)
17
The CT362A (0.67 kW) is more powerful than the CT369 (0.552 kW).
CT369 12-volt Starter KMZ CT369
Fits: Dnepr, Ural
Item: CT369
List Price: $129.95
(dnepr-kiev.com)
KMZ CT369
Fits: Dnepr, Ural
Item: CT369
List Price: $142.95
(www.amazon.com)
18
The CT362A (0.67 kW) is more powerful than the CT369 (0.552 kW).
The High Torque and Poor Metallurgy Accounts
for the Cracked Bell on My Electric Starter (2003 Patrol)
CT369
19
Another Ural Starter (CT369) Failure (www.russianiron.com)
• Bell Housing on 750cc Electric Starter Cracked
• New Starter from Stock Is Longer than Previous Starter
• Kick-Start Lever Interferes with Electric Starter Body
157 mm / 6.2”
ИМЗ-8.124-18075-10
CT369Б (ИМЗ-8.124-18075)
List Price: 7,870 ruples
(www.mazepper.ru)
22
The “.3708” is merely the govt. engineering
group code for starters, not really necessary.
Modified Kick-Start Levers
•Factory-Supplied, Replacement Motors (CT369Б) Are about 1”
Longer than the Original CT369 Starter Motors Kick-Start
•No Problem for Russian Outboard Engines (Major Market) Lever
–Plenty of Leg-Room in Outboard Engine Compartment with
“bend”
•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 - Long. The longer motor is current fitment to all electric start
Urals. It can be fitted as a replacement for the earlier short type motor, but you will
require a new kick-start lever with a greater offset to clear the back of the starter
motor.
Part #: F24320/LONG
List Price: £245.00
(www.f2motorcycles.ltd.uk)
23
CT362A
ST362A Starter-Motor
Part #: CT362A.3708000
Place of Origin: cheetszyan, China
Car Make: Ukraine Tractor 362A
Vendor ID: 242659521 25
(russian.alibaba.com
Starter-Motors: СТ-362
26
The CT362 starter-motor has been discontinued.
Starter-Motor 3708 CT-362
http://www.ziand.com/html/ru/catalog/Starting_Engine/Starter_ST362.htm
1. Relay cover
2. Gasket
3. Spring
4. Lock washer
5. Washer
6. Bar
7. Washer
8. Washer
9. Spring
10. Washer
11. Bolt pin
12. Stock
13. Nut
14. Washer
15. Yoke 43. Cover
16. Spring 44. Spring Brush
17. Housing 30. Ring 45. Gasket
18. Anchor (Movable Core) 31. Gear 46. Cap
19. Lever 32. Spring 47. Bolt
20. Gasket 33. Cup Sleeve 48. Washer
21. Cover 34. Washer 49. Washer
22. Washer 35. Bearing Cup 50. Screw
23. Lever Axis 36. Ring 51. Washer
24. Pin 37. Insulated Brush 52. Nut
25. Screw 38. Anchor 53. Nut
26. Insert (d=9mm, D=13.8, L=13mm) 39. Brush Holder 54. Washer 27
27. Washer 40. Brush Bare 55. Finger
28. Washer 41. Insert d= 9mm, D= 13,8, L= 13mm 56. Bolt M10x30
29. Ring 42. Ring 57. Washer
Servicing the СТ362 (ST362) (tractor-mtz80-mtz82.ru)
•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
Gasket
Notice the cute little bend in the kick-start lever for later (from 2006)
model Urals to handle the longer CT369Б starter motors. 29
Specify color or chrome when ordering.
Gear Case for Mounting Starter-Motor (650/750cc)
Mounting Flange
for Starter-Motor Kick-Start Lever
Bell Cover
31
The CT369 is the “A” version of the Ural electric-start motor (shorter version).
369Б.3708 and 392.3708
The End-Cap of the Later Version (CT369Б) Extends
about 25mm Beyond the Electrical Terminals.
369Б.3708
392.3708
Old Timer Garage supplies two types of starter-motors, the 392.3708 for the Ural,
which is the shorter version; and the 369Б.3708 for the Dnepr, 32
which is the longer version).
CT369Б Electric Starters
Electric Starter
(Ural 750/650)
Part #: IMZ-8.124-18075
Vendor ID: 1725
List Price: €245.14
(www.ural-europa.com)
Electric Starter
Part #: IMZ-8.124-18075 Electric Starter - Long. The longer motor is current fitment to all
Engine: 650/750 electric start Urals. It can be fitted as a replacement for the earlier
List Price: $300 short type motor but you will require a new kick-start lever with a
http://www.ural.ca/parts.html greater offset to clear the back of the starter motor.
Part #: F24320/LONG List Price: £245.00 (www.f2motorcycles.ltd.uk)
33
The CT369Б Electric Starters are the newer, longer electric starters for Urals.
Suppliers of Ural Electric Starters
Ural Electric Starter
List Price: 4,999 rubles
(www.mc78.ru)
or
Ural Electric Starter
List Price: 4,350 rubles
(750cc.ru)
369.3708
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
35
terminals, discharging, worn or hung brushes, or oxidation of the commutator.
1998 Ural Deco with Hitachi Starter-Generator
• Late '98 was the first of the Electric Starter for Ural
Front
Front
36
18-Amp Hitachi Starter-Generator
On many models, the silicone Diode is
. .
mounted across the large terminals of
the Starter Solenoid Middle Prong Ignition
Large Of Top Row Switch Fuse
White
Wire
#2 to Horn &
Beefy Brake Lights
Terminals
Starter
Momentary
+ Solenoid Starter Button Note: Two wires to
(black, on handlebar) handlebar button.
Charge
12-Volt
Battery
- Small
S Small Generator Fault Lamp
.
Black
Red Isolation Wire (red, lights when battery voltage
Wire
Switch is greater than charging voltage
Diode extinguishes at high rpm when
charging)
Installed on Some Models,
Used to Keep Battery from Large
.
Discharging Over Long-Term Storage Grey
(if not present, replaced with a wire) Wire D+
Hitachi
A1
. F2 DF
Regulator Coil
Voltage Regulator
Starter-Generator
(18-Amp, 0.9HP
.
GSB107-04A, Up tocCharging voltage,
DF the winding current is
Five-Terminal) 30Ω Resistor max, as the FF terminal is
effectively grounded. As
A2 F1 Voltage at D+ increases,
the relay pulls-In,
Armature (A) reducing the winding
(Rotor) Field (F) Winding 10Ω Resistor D-
(Stator) current by placing a 10Ω
resistor in series.
DT Stands for
Dynamo Field
37
Optional Electric Start on Early 650cc Urals
(2001 Owner’s Manual)
Up until 2006, Urals used the CT369 electric starters, which allowed
straight kick-start levers. After that, the kick-start levers needed to be
39
modified to avoid interference with the longer replacement starter-motor.
Ural 650/750cc Starter/Alternator Circuit (2002-2003) with 35-Amp Alternator
Front View of
Socket or Relay Under Seat
Right Handlebar
87
grn / red RY-115 RY-115
Momentary Electric Start Electric Start
“Start” “Start”
86 85
Relay #1 Relay #2 Starter Solenoid
Button (Normally Open) (Normally Open)
yel / red 30
Rocker-Arm red
“Run / Kill” + - Starter Motor
Switch “Kill” “Run”
Ignition
.
pnk/ blk Module 85 86 30 87 85 86 30 87
white
Headlight Cavity 9-pin
Connector red black
white
(+12V. in “Run” position) green
Neutral + Main
large
Switch white
Green Output large
(Neutral) gray 35 Amp Russian (ring) black
(Hand Grenade)
blue
Pos +
.
+ Fault
Red (face-side) (back-side) green Terminal 12 Volt
(spade) Battery
(Alternator In-Line Fuse #1
Fault) red
(0V: Engine not running, Neg -
top red +12V: Engine running and
Alternator working.)
red 4 Notes:
Ignition 1. In-Line Fuse #1 (15A) for Turn Signal and
Brakes 3 Neutral Indicator Lamp. Chassis
Switch 2. Fuse Block #4 Fuse (5A) for Ignition and Ground
Headlites Electric Start Relays.
1
6 5 1 2 3
Connector Pin
Run Lites
2
(+12V. When Ignition Switch on “Run”)
bottom Male Female
Ignition Key
Fuse Block 40
Terminal
Replacement 12-Volt Starter on My 2003 Patrol
CT369Б (ST369B)
Notes:
Right Handlebar 1. Two Start Relays (RY-115)
87
2. In-Line Fuse #1 deleted mid-2005
grn / red RY-115 RY-115
Momentary Electric Start Electric Start
“Start” “Start”
86 85
Relay #1 Relay #2 Starter Solenoid
Button (Normally Open) (Normally Open)
yel / red 30
Rocker-Arm red
+ - Starter-Motor
“Run / Kill”
Switch “Kill” “Run”
Ignition
.
pnk/ blk Module 85 86 30 87 85 86 30 87
white
Headlight Cavity 9-pin
Connector red black
.
white
(+12V. in “Run” position)
Neutral blue large
Switch grey
55 Amp Nippon-Denso large
gray Alternator + Main black
red
Output
Green
(Neutral)
IG Pos +
Red
(Alternator
Fault)
. red
(face-side)
top
(back-side)
In-Line Fuse #1
red
Notes:
green
(0V.: Engine not running
(lamp) IG
+12V.: Engine running and
(ignition)
Alternator working.”)
L
L
12 Volt
Battery
Neg -
red 4
1. In-Line Fuse #1 (15A) for Turn Signal
Ignition Brakes and Neutral Indicator Lamp.
3
2. Fuse Block #4 Fuse (5A) for Ignition & Chassis
Switch Electric Start Relays. Ground
Headlites 1
6 5 1 2 3
Connector Pin
Run Lites 2
(+12V. when Ignition Switch on “Run”) Male Female
bottom 42
Ignition Key Fuse Block
black Terminal
Ural 750cc Starter Circuit (2006-2007) Single-Relay
Notes:
Right Handlebar
1. Single Start Relay (RY-115)
Momentary 2. ND Alternator added 2004
“Start” grn/red
87 3. In-Line Fuse #1 Deleted mid-2005
Button RY-115
“Start”
Electric Start Relay Starter Solenoid
yel/red 86 85
(Normally Open)
30
Rocker-Arm
“Run / Kill” red + -
Switch “Kill” “Run” Ducati Starter-Motor
pnk/blk
Ignition 85 86 30 87
Headlight Cavity D E F G Module
16 red
18 brn/red
10-pin Connector
18 pnk
. 18 brn/red
18 brn/red
12 red
8 red
Neutral
Green Switch
(Neutral) 18 blk/red
IG Pos +
12 Volt
Fuse Block L Battery
Red 18 blk/red
(Alternator 15A
Neg -
18 pnk/blk
Fault) 8 blk
18 pnk/blk 5A
Ignition 14 blu L
(lamp)
Switch 15A IG Chassis
(ignition) Ground
5A
18 blu
14 blu Connector Pin
5 6 1 2 3
12 red Male Female
43
Note: # in front of wire color is AWG wire size. Terminal
Ignition Key
Ural (Урал) 2010-2011 (750cc)
Starter-Motor
and Solenoid
55 Amp
Nippon-Denso
Alternator
44
Ural (Урал) IMZ-8.1037 (with Electric-Start)
Starter-Motor
and Solenoid
45
Ural Electric Starters (2003 – 2017)
# Part # Description
4 IMZ-8.1037-18075: Part no longer
produced. (2003 – 2015) IMZ-8.1037- Starter
18075-01 should be ordered)
5 DIN 912 M10x45 Screw М10-6gх45
6 DIN 912 M10x25 Screw М8x25 8.8 ZN
7 Gasket 1 mm thick , for adjustment of
IMZ-8.124-18113 starter crown gear position when
required.
8 Gasket 2 mm thick , for adjustment of
IMZ-8.124-18112 starter crown gear position when
required.
13 DIN 7985 M6x12 Screw М6-6gх12
14 IMZ-8.1037-18111 Specify color. Cover
Electric start is available on the Patrol, Gear-Up and Retro Sidecar (2003-2017),
Tourist (2003-2013),Patrol T and T (2009-2014), and cT (2015-2017). 46
RY-115 Electric Start Relay