Motorcycles: Fundamentals, Service, and Repair

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ISBN: 9781566374798 | 1566374790
Cover: Hardcover
Copyright: 12/1/1998

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Motorcycles covers the important aspects of the operation, construction, design, testing, maintenance, and repair of motorcycle systems and components. This title also includes operation and service material relative to all-terrain vehicles (ATVs) and small scooters/mopeds. Content is written in nontechnical language with step-by-step procedures to assist learning. This edition is up-to-date with today's theory and service procedures.

CHAPTER 1 INTRODUCTION TO MOTORCYCLES, ATVs, AND SCOOTERS

(30)

The Role of Qualified Service Technicians

(1)

Styles and Designs of Motorcycles, ATVs, and Scooters

(1)

Engine

(2)

Engine Parts

Four-Stroke Cycle Engine

(1)

Four-Stroke Cycle Engine Operation

(3)

Two-Stroke Cycle Engine

(1)

Two-Stroke Cycle Engine Operation

Engine Power Characteristics

(1)

Work and Energy

Torque and Power

Horsepower

Fuel System

(3)

Carburetor / Electronic Fuel Injection

Electrical System

(1)

Starting System / Charging System / Ignition System

Cooling System

(5)

Air Cooling / Liquid Cooling

Lubrication Systems

(1)

Exhaust System

(1)

Power Transmission

(1)

Gear Action / Primary Drive / Clutch

Transmission / Final Drive

Chassis

(1)

Frame

(1)

Suspension

(2)

Suspension Operation

Wheels and Tires

(1)

Brakes

(1)

Accessory System

(5)

CHAPTER 2 SHOP SAFETY AND ENVIRONMENTAL PROTECTION

(8)

Safety Notices

(1)

Personal Safety

(2)

Proper Dress

Protective Equipment

Shop Hazards

Work Properly

Vehicle Safety Rules

Fire Prevention

(1)

General Fire Safety Rules

Using a Fire Extinguisher

Environmental Protection

(4)

Hazardous Materials

Right-to-Know Laws

Handling Hazardous Waste

CHAPTER 3 TOOLS, MEASURING INSTRUMENTS, AND SHOP EQUIPMENT

(28)

Tools and Equipment

(1)

Tool Boxes

(1)

Hand Tools

(9)

Wrenches

Screwdrivers

Sockets and Socket Drivers

Pliers

Allen Wrenches

Hammers

Files

Punches, Chisels, and Pry Bars

Hacksaw

Engine Service and Repair Tools

Power Hand Tools

Proper Care and Use of Tools

General Shop Equipment

(1)

Electrical Test Equipment

Measurement

(8)

Outside Micrometer

Inside Micrometer

Depth Micrometer

Dial Caliper

Telescoping Gauge

Dial Indicator

Dial Bore Gauge

Feeler Gauge (Wire Gauge)

Plastigage

Pressure and Vacuum Measurements

Spring Rate Measurement

Fluid Volume Measurement

Care of Precision Measuring Tools

Parts Cleaning

(2)

Methods of Cleaning

Special Operations

(7)

Boring Bar

Lathe and Vertical Mill

Drill Press and Drills

Resurfacing Parts

Grinders

Hydraulic Press

Welding

CHAPTER 4 FASTENERS, GASKETS, AND DIAGNOSTIC PROCEDURES

(24)

Fasteners

(9)

Bolt and Screw Terminology

Nuts

Studs

Machine Screws

Washers

Torquing Fasteners

Thread Repairs

Nonthreaded Fasteners

Gaskets and Seals

(3)

Gaskets

Seals

Adhesives

Using Service Manuals

(2)

Service Manual Types

Technical Bulletins

Owner's Manuals

Diagnostic Procedures

(5)

Verifying the Problem

Analyzing the Problem

Types of Problems

How to Troubleshoot

Troubleshooting Steps

Service Tips

(5)

CHAPTER 5 BASIC ELECTRICAL AND ELECTRONIC THEORY

101

(20)

Electrical Theory

101

(5)

Electricity

Electric Current

Electrical Circuits

Units of Electricity

Electrical Terms and Components

Motorcycle Electronics

106

(2)

Diode

Sources of Electricity

108

(1)

Battery

Magnetism

Motorcycle Wiring

109

(1)

Wire Types

Electrical Schematics and Symbols

110

(1)

Schematics

Electrical Systems Maintenance and Testing

111

(2)

Basic Electrical Test Equipment

Basic Electrical Diagnostic Methods

113

(8)

Using Test Equipment in Troubleshooting

Measuring Resistance

Measuring Current

Electrical System Repairs

Soldering

Crimp Terminals

Heat-Shrink Tubing

CHAPTER 6 ENGINES

121

(24)

Four-Stroke Engines

121

(1)

Valve Train

122

(1)

Camshaft Arrangement

122

(1)

Single Overhead Camshaft (SOHC)

Dual Overhead Camshaft (DOHC)

Camshaft Design

Pistons, Crankshafts, and Cylinders

123

(8)

Single Cylinder Engine

Twin Cylinder Engine

Multi-Cylinder Engines

Cylinder Design and Construction

Piston Construction and Design

Combustion Chamber Design

Piston Ring Grooves

Piston Rings (Four-Stroke)

Four Cycle Engine Bearings

Engine Case

131

(1)

Non-Unit Construction

Unit Construction

Vertical and Horizontal Split Crankcases

Two-Stroke Engine

131

(3)

Intake Timing

Piston Port

Reed Valve

Rotary Valve

Transfer and Exhaust Timing

134

(1)

Crankcase Sealing

134

(1)

Crankshaft Configurations

134

(2)

Single Cylinder Crankshaft

Twin-Cylinder Crankshaft

Multi-Cylinder Crankshaft

Piston and Ring Design

136

(3)

Transfer Cutouts

Ring Locating Pins

Intake Skirt

Piston Expansion

Piston Rings

Cylinder Construction

139

(3)

Pressed-In Sleeve

Cast-In Sleeve

Coated Bore

Cast Iron Cylinder

Cylinder Ports

Vertical and Horizontal Split Crankcases

142

(3)

CHAPTER 7 FUEL SYSTEMS

145

(38)

Fuel System Parts

145

(3)

Fuel Tank

Fuel Petcock

Fuel Line

Fuel Pump

Fuel Filter

Air Filter and Intake Manifold

Throttle Twist Grip

Throttle Cable

Gasoline

148

(2)

Carburetors

150

(1)

Fuel Atomization and Combustion

Air-Fuel Ratio

Venturi Principle

Positive Carburetor Linkages

Common Carburetor Types

151

(11)

Slide Carburetors

Vacuum Controlled Carburetor

Butterfly Controlled Carburetor

Carburetor Adjustment

162

(4)

Idle Mixture

Idle Speed

Synchronization

Float Level

Throttle Cable Adjustment

Changing Carburetor Jets

Carburetor Rebuilding

166

(3)

Carburetor Removal

Carburetor Disassembly

Carburetor Cleaning

Parts Inspection and Replacement

Carburetor Reassembly

Carburetor Installation

Final Carburetor Adjustment

Carburetor Rebuilding Summary

169

(2)

Electronic Fuel Injection

171

(1)

Function of EFI Components

171

(5)

Electronic Control Module (ECM)

EFI Intake Air System

Fuel Injector

Throttle Body

EFI Pressure Regulator

Sensor System

Engine Control System Operation

176

(1)

ECM Self-Diagnostics

177

(6)

Using the EFI Warning Light

Checking the Fault Code with a Voltmeter

CHAPTER 8 BATTERY and CHARGING SYSTEMS

183

(24)

Batteries

183

(8)

Battery Safety Precautions

Battery Operation

Battery Service

Battery Testing

Troubleshooting Battery Problems

Alternators

191

(4)

Alternator Operation

Ac Charging Systems

Permanent Magnet Alternator

Electromagnet Alternator

Flywheel Magneto

Dc Generator

195

(1)

Charging System Rectification and Regulation

196

(2)

Rectifiers

Voltage Regulators

Charging System Service

198

(3)

Parasitic Draw Test

Voltage Output Test

Current Output Test

Stator Continuity Test

Charging Coil Test

Charging System Troubleshooting

201

(1)

Electric Starting Motor

201

(6)

CHAPTER 9 IGNITION SYSTEMS

207

(20)

Ignition Systems

207

(6)

Ignition Triggering

Ignition Coil

Ignition Timing

Frequency of Spark

Spark Plug

Spark Plug Wires

Types of Ignition Systems

213

(10)

Battery and Coil Ignition

Electronic (Transistorized) Ignition

Flywheel Magneto Ignition System

Digitally Controlled Transistorized Ignition System

Capacitor Discharge Ignition (CDI)

CDI Ignition System

Ignition Problems

223

(4)

Engine Does Not Start, Starting Difficulty

Poor Running at Low Speed

Poor Running or No Power at High Speed

CHAPTER 10 LUBRICATION SYSTEMS

227

(18)

Friction

227

(1)

Oil

227

(3)

Lubricating Action

Cleaning Action

Cooling Action

Sealing Action

Oil Types

API and SAE Oil Classifications

Two-Stroke Engine Lubrication

230

(4)

Premix Lubrication

Oil Injection Lubrication

Oil Injection System Maintenance

Primary Drive and Gearbox Lubrication

Four-Stroke Engine Lubrication

234

(5)

Dry Sump Lubrication

Wet Sump Lubrication

Common Sump Lubrication

Oil Pump Types

Check Valves

Relief Valves

Oil Filters

Oil Cooler

Lubrication System Maintenance

239

(3)

Checking Oil Levels

Leak Inspection

Changing Oil and Filter

Oil Pressure Check

Troubleshooting Lubrication Systems

242

(3)

Two-Stroke Engines with Oil Injection System

Two-Stroke Engines Using Premixed Oil

Four-Stroke Engines

CHAPTER 11 COOLING SYSTEMS

245

(12)

Air-Cooled Engines

245

(1)

Liquid-Cooled Engines

246

(1)

Liquid-Cooled System Components

246

(4)

Coolant

Radiator

Recovery Tank

Radiator Cap

Thermostat

Water (Coolant) Pump

Cooling Fan

Hoses and Clamps

Servicing and Troubleshooting Air-Cooled Systems

250

(1)

Servicing Liquid-Cooling Systems

250

(7)

Coolant Check

Flushing the Cooling System

Testing the Radiator Cap

Testing the Thermostat

Water Pump Service

Checking and Replacing Hoses

Troubleshooting Liquid-Cooling Systems

CHAPTER 12 EXHAUST SYSTEMS AND EMISSIONS CONTROL

257

(16)

Exhaust Systems

257

(1)

System Descriptions

257

(3)

Exhaust Pulse Scavenge Effect

Common Exhaust Pipe

Spark Arrester

Inspecting and Servicing Exhaust Systems

260

(1)

Turbochargers

261

(1)

Emission Control Systems

262

(6)

Evaporative Emission Control

Catalytic Converters

Noise Control Systems

268

(5)

CHAPTER 13 POWER TRANSMISSION SYSTEMS

273

(32)

Primary Drive

273

(2)

Primary Gear Drive Systems

Primary Chain Drive Systems

Primary Belt Drive Systems

Clutches

275

(6)

Multi-Plate Clutch

Clutch Springs

One-Way Clutches

Centrifugal Clutch

Manual Transmissions

281

(1)

Transmission Shafts

Multi-Speed Transmissions

Internal Gear Changing

282

(5)

Gear Selector Mechanisms

Drum Gear Selector

Cam Plate Gear Selector

Transmission Indexer

Neutral Indicator Switch

Shift Drum Location Device

Shift Stopper

Gear Engagement

Transmission Types

Automatic Transmissions

287

(4)

Automatic Centrifugal Clutch

Belt Transmissions

Planetary Gearshifts

Final Drive Systems

291

(14)

Chain Final Drive

Belt Drive

Shaft Drive System

Final Drive Ratio

Overall Ratio

Starting Systems

Kickstart Mechanisms

Starter

Ignition Systems

Starting System (Starter Motor) Operation

CHAPTER 14 WHEELS AND TIRES

305

(22)

Wheels

305

(2)

Wire Wheels

Cast Wheels

Stamped Wheels

Wheel Inspection

307

(1)

Wheel Service

308

(4)

Repacking or Replacing Wheel Bearings

Tightening Loose Spokes

Replacing Broken Spokes

Replacing a Dented Rim

Lacing and Truing a Wire Wheel Assembly

312

(1)

Wheel Lacing Procedure

Wheel Truing

Final Tightening of Spokes

Tires

313

(14)

Tire Design

Tire Inspection

Tire Service

Tire Storage

Troubleshooting Wheels and Tires

CHAPTER 15 BRAKES

327

(26)

Brake Operation

327

(3)

Mechanical Brake System

Hydraulic Brake System

Brake Design

330

(5)

Drum Brakes

Disc Brakes

Brake Fluid

Brake Inspection, Maintenance, and Repair

335

(8)

Front Wheel Removal

Installation

Rear Wheel Removal

Installation

Brake Service

Hydraulic Disc Brake System

Master Cylinder and Caliper Rebuilding

Unified Brake Controls

343

(1)

Linked Braking System (LBS)

343

(2)

Anti-Lock Brake Systems (ABS)

345

(3)

Functions of ABS Components

Fail Safe Relay

ABS Operation

Troubleshooting Motorcycle Brake Systems

348

(5)

Mechanical Drum Brakes

Hydraulic Disc Brakes

ABS System

CHAPTER 16 FRAME AND SUSPENSION SYSTEMS

353

(26)

Frame

353

(3)

Cradle Frame

Backbone Frame

Diamond Frame

Delta-Box Frame

Pentagonal Frame

Stamped Frame

Frame Inspection

356

(1)

Front Suspension

357

(10)

Telescopic Front Suspensions

Pivoting Link Front Suspension

Single-Sided Swingarm Front Suspension System

Steering Geometry

Rake

Steering Damper

Servicing Front Suspension Components

Rear Suspension Systems

367

(6)

Shock Absorbers

Side Stand

Frame and Suspension Inspection

373

(1)

Front Suspension Inspection Summary

Mid-frame Inspection

Rear Suspension Inspection

ATV Four Wheel Alignment

Frame Problems

374

(1)

Front Suspension Problems

375

(1)

Rear Suspension

375

(4)

CHAPTER 17 ACCESSORY SYSTEMS

379

(16)

Accessory Systems

379

(1)

Lighting Systems

379

(5)

Headlights

Tail Lights

Brake Light

Turn Signal Indicator Lights

Instrument Panel

Lighting System Problems

384

(2)

Warning and Indicator Circuits

386

(4)

Oil Pressure Warning Light (Four-Stroke Engine)

Oil Level Indicator (Two-Stroke Engine)

Coolant Temperature Gauge

Fuel Level Gauges

Brake Fluid Warning Light

Charging Gauges

Check Engine Light

Side Stand Indicator Light

Anti-Lock Brake Light

Speedometer

Tachometer

Switches

390

(1)

Horn Circuit

Communication Systems

391

(1)

Cruise Control

392

(3)

CHAPTER 18 ENGINE AND POWER TRANSMISSION DISASSEMBLY

395

(14)

Preparing for Engine Removal

395

(1)

Clean the Vehicle

Is Engine Removal Necessary?

Read the Service Manual

Drain Fluids

396

(1)

Disconnect Electrical System

396

(1)

Electrical and Wiring Disconnects

Disconnect Control Cables

397

(1)

Fuel System Disassembly

398

(1)

Carburetor Removal

Fuel Injection System Disassembly

Disconnect Final Drive

398

(1)

Removing Engine from Motorcycle

398

(1)

Follow Safety Rules

Engine Stand

Engine Removal Summary

399

(3)

Organize Parts

Storage Containers

Tags and Markings

Engine Fasteners

Mating Parts

Shims and Thrust Washers

Dividing the Engine

402

(1)

Engine Top and Bottom End

Engine Left and Right Side

Transmission

Holders and Pullers

403

(2)

Engine Holders

Pullers

Using Heat to Aid Disassembly

405

(1)

Heat Use Warnings

Sequence of Disassembly

406

(3)

Typical Engine Disassembly Problems

CHAPTER 19 TWO-STROKE ENGINE OVERHAUL

409

(22)

Engine Top End Service

409

(1)

Cylinder and Piston Inspection

409

(4)

Cylinder Problems

Piston Damage

Piston and Cylinder Measurement

Engine Decarbonizing

413

(1)

Parts Reconditioning and Replacement

414

(1)

Cylinder Boring and Honing

Engine Lower End Service

415

(4)

Measuring Rod Big End Bearing Clearance

Connecting Rod Side Play

Main Bearings

Crankshaft Wheel and Axle Condition

Crankshaft Reconditioning

Engine Diagnosis

419

(5)

Normal Wear

Lubrication Failure

Foreign Material Damage

Overheating

Checking Crankshaft and Transmission Shaft End Play

Engine Reassembly

424

(1)

Lip Seal Installation

Oil and Grease Types

Checking for Binding After Each Installation

Sealants

Rotary Valve Timing

Top End Reassembly

425

(2)

Torque Sequence

Crankcase Leak Test

Ignition Timing

Engine Reassembly Summary

427

(1)

Installing Engine in Frame

427

(1)

Initial Engine Start-Up and Operation

428

(3)

CHAPTER 20 FOUR-STROKE ENGINE OVERHAUL

431

(32)

Engine Top End Service

431

(12)

Cleaning and Decarbonizing

Top End Inspection and Measurement

Checking Camshafts for Wear

Reconditioning the Cylinder Head Assembly

Cylinder Head Reassembly

Piston and Cylinder Inspection and Service

Engine Bottom End Service

443

(7)

Inspection and Measurement of Bearings

Checking Oil Pump Condition

Cleaning Oil Passages and Bottom End Filters

Diagnosis of Oil System Problems

Engine Balancer Inspection

Crankshaft Measurement and Reconditioning

Connecting Rod Reconditioning (Plain Bearing)

Engine Measurement and Inspection Summary

Four-Stroke Engine Reassembly

450

(13)

Plain Bearing Installation

Crankshaft and Transmission Shaft Installation

Oil and Grease Use

Sealing Compounds

Timing of Engine Balancers

Torque Sequence and Value

Piston Ring Installation

Piston Installation

Cylinder Installation

Cam Timing

Four-Stroke Engine Reassembly Summary

Engine Installation

Initial Engine Running

Engine Break-In Procedures

Post-Overhaul Checkup

CHAPTER 21 POWER TRANSMISSION OVERHAUL

463

(22)

Primary Drive Service and Repair

463

(2)

External Chain Primary Drive Service

Internal Chain Drive Service

External Gear Primary Drive Service

Internal Gear Primary Service

Clutch Service and Repair

465

(5)

Clutch Basket, Bearing, and Hub Wear

Friction and Plain Plate Service

Clutch Spring Service

Primary Kickstart Inspection

Primary Drive and Clutch Inspection Summary

Primary Drives and Clutch Reassembly

Transmission Service and Repair

470

(7)

Shaft End Play

Shift Mechanism Operation

Transmission Disassembly

Transmission Measurements

Kickstart Mechanism Inspection

Transmission Reassembly and Shimming

Transmission Reassembly Summary

Final Drive Service and Repair

477

(8)

Chain Drive

Drive Belt Drive Inspection and Service

Engine Starts but Vehicle Will Not Move

Engine Stalls or Vehicle Creeps

Poor Performance at High Speeds or Lack of Power

Shaft Drive Inspection, Service, and Repair

Final Drive Problems

CHAPTER 22 TUNE-UP AND GENERAL SERVICE

485

(22)

Preparing to Tune-Up a Motorcycle

485

(1)

Inspection

485

(1)

Computer Control System Check

486

(1)

Replacing Air and Fuel Filters

486

(1)

Battery Service

487

(1)

Checking Cooling System

487

(1)

Engine and Chassis Lubrication

488

(1)

Tire and Wheel Service

488

(1)

Replacing Spark Plugs

489

(1)

Measuring Engine Compression and Leak-Down

489

(3)

Compression Testing

Cylinder Leak-Down Testing

Ignition System Tune-Up

492

(2)

Contact Point Ignition System Service

Ignition Timing Adjustment

494

(3)

Static Ignition Timing Adjustment

Dynamic Timing Adjustment

Electronic Ignition System Service

497

(1)

Air Gap Adjustment

Engine and Carburetor Tune-Up

498

(1)

Valve Adjustment

498

(1)

Cam Chain Adjustment

498

(2)

Carburetor Pilot Circuit Adjustment

500

(1)

Carburetor Synchronization

500

(1)

Idle Speed Adjustment

500

(1)

Tune-Up and General Service Summary

501

(6)

Periodic Maintenance Schedule

Documentation

CHAPTER 23 THE BUSINESS OF MOTORCYCLE, ATV, AND SCOOTER SERVICE

507

(8)

Employment in the Motorcycle Industry

507

(1)

Dealership

Service Shops

Job Classifications

508

(1)

Service Technician

Service Writer

Parts Manager

Service Manager

Marketing and Sales

Storage

509

(1)

Storage Preparation Procedures

Returning the Bike to Service

Liability

510

(2)

Unsafe Conditions

Inspecting for Unsafe Conditions

Correcting Unsafe Conditions

Preventing Liability Problems

Warranty

Working in the Field

512

(3)

Appendix A

515

(38)

Diagnostic Charts

515

(12)

Conversion Charts

527

(7)

Abbreviations

534

(3)

Glossary

537

(16)

Index

553

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Motorcycles: Fundamentals, Service, and Repair

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Table of Contents

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