The Complete Guide to

Motorcycle Mechanics Second Edition

MOTORCYCLE MECHANICS INSTITUTE A Division of Clinton Technical Institute

Phoenix, Arizona Orlando, Florida

PR ENTICE HALL CAREER & TECHNOLOGY, Upper Saddle River, New Jersey 07458

Contents

PREFACE. xi

ACKNOWLEDGMENTS, xiii

NO~ TO READER, xv

1 WORKING IN THE MOTORCYCLE INDUSTRY, 1

Industry Growth 1 Job Opportunities 1 Where to Train 3

2 MEASUREMENT SYS~MS, 5

A Brief History 5 The Metric System 6 Conversions 7 Using Measurement Tools 11

3 I~RNAL COMBUSTION ENGINE THEORY, 17

Pbysical Laws Involved in Combustion 17 The Internal Combustion Process 18 Factors InfI.ueocing Combustion and Engine Performance 18 Abnormal Combustion 21 Engine Design and Combustion 23 Factors Determining Efficient CombustiOD 2S

v

4 TIlE FOUR-STROKE ENGINE, 28

Four-Stroke Engine Components 28 Four-Stroke Engine Operation 30 Four-Suoke Engine Designs 31 Four-Suoke Engine Components 36

5 TIlE TWQ.STROKE ENGINE, 71

Two-Suoke Engine Components 71 Two-Suoke Engine Systems 80 Two-Stroke Engine Designs 85 Two-Stroke Engine Operation 85 Two-Stroke Engine Formulas 92 Two-Stroke Engine Service and Adjustments 93

6 THE DRIVE TRAIN AND STARllNG SYSTEMS, 96

Principles of Operation 96 Primary Drive Systems 98 Outch 101 Transmission 110 Final Drive System 115 Servicing Drive Systems 120 Starting Systems 124 Servicing Starting Systems 127

7 LU BRICA llDN AND COOUNG SYSTEMS, 129

The Composition of Oil 129 The Purpose of Lubrication 130 Properties of Oil 131 Oil Testing and Classification 133 Four-Stroke Engine Lubrication Systems 134 Servicing Four-Stroke Lubrication Systems 136 Two-Stroke Engine Lubrication Systems 138 Servicing Two-Stroke Engine Lubrication Systems 139 Troubleshooting Lubrication Systems 140 Cooling Systems 140 Principles of Heat Transfer 140 Cooling System Designs 140 Servicing Cooling Systems 143

8 FUEL SYSTEMS AND CARBUREllON, 147

Fuel System Components 147 Servicing Fuel Systems IS2 Fuel 152 Motorcycle Emissions 153 Carburetion 157

Contents

Contents vii

Principles of Carburetion 157 Basic Carburetor Components 157 Basic Operation 160 CarburetorDesigns 161 Servicing Carburetors 168 Cold-Starting Systems 171 Electronic Fuel Injection 171 Twbocbargmg 174

9 BASIC ELECTRICAl THEORY. In

Principles of Electricity 177 Basic Terminology 178 Current 180 Measuring Electrical Power 183 Principles of Magnetism 185 Producing Electricity 186 The Lead-Acid Battery 188 Battery Service and Testing 190 Low-Mainteoance Batteries 193 Test Equipment 193 Voltage Drop 195

10 IGNmON SYSTEMS. 197

Ignition System CoDllX'nents 197 Testing and Servicing Ignition System Components 205 Factors Affecting Ignition 212 Ignition Systems 213 Troubleshooting Ignition Systems 219

11 CHARGING SYSTEMS AND STARTER MOTORS. 221

Principles of Operation 221 Checking Charging Systems 222 Ac Charging System Designs 224 Testing Ac Charging Systems 230 Dc Clwgmg Syst= Designs 23S Testing Dc Charging Systems 238 Starter Motors 240 Testing Starter Motors 240

12 UGH11NG AND ACCESSORY SYSTEMS. 242

Lighting Systems 242 Warning Systems 246 Safety Systems 249 Accessory Systems 250

viii

13 WHEELS AND T1RES, 252

Basic Wheel Components 252

Wheel Designs 252 Wheel Maintenance 256

Minor Wheel Repairs 258

Tires 263 Tire Selection 264

Tire Maintenance and Repair 266

14 FRAME AND SUSPENSION, 269

Frame Construction 269

Frame Design 269 Frame Components 272

Frame Maintenance 276

Suspension 277

Factors AffectiJ!.g Suspension 278

Rear Suspension Components 282

Front Suspension and Steering 286

Steering Geometry 29 1

Troubleshooting Handling Problems 292

15 BRAKE SYSTEMS, 294

A Brief History 294 Brake Systems 294

floating Brake Mounts 302

Antidive Sys[emS 302

Unified Brake Systems 304

Servicing Brake Systems 304

Servicing Antidive Systems 307

16 SHOP SAFElY AND TOOLS, 308

Shop Safety 308 Special Tools 309 Hand Tools 309

Fasteners 319 Thread Repair 325

17 FOUR-STROKE ENGINE TUNE-UP AND SERVICE, 327

Basic Tune-Up and Service Procedures 328

18 TWO-STROKE ENGINE TUNE-UP AND SERVICE, 337

Basic Tune-Up and Service Procedures 338

Contents

Contents

19 RIDING SAFETY. 345

Elements of Riding Safery 345

APPENDIX. 352

English-to-Metric ConversioD. Table 352 Metric-to-English COD.version Table 353

GLOSSARY. 354

INDEX. 367

A

Abnormal combustion., 21-23 Accessory systems, 25~251

audio systems, 250-251 cruise control, 251

Ac charging systems. Su Charging systems: ac charging systems

Accidents. See Riding safety Ac output voltage testing. 224 Active combustion, 18 Additives, to fuels, 153 Air cooling system(s)

described, 142-143 service, 146 two-stroke engines., 85

Air filter fuel system component, 150-151 mne·up and service (four-stroke engine), 331-332 mne-up and service (two-stroke engine), 340

Air/fuel mixrure engine performance. 20 turbulence and, 24 two-stroke engine service and adjusanenLS, 93

Air-oil forks, front fork design, 290-291 Air pressure, tire maintenance and repair, 266 Air screw adjustment, carburetor service, 168 AlIen-head sockets. 314 Altemating-current How, electrical theory, 180 Alternator. ac cbarging system, described, 228

Index

American Society for Testing Materials (ASTE), 320 Ammele<, d=ribed, 194 Ampere-bour capacity. battery. 190 Antidive systems, 302-304, 307 Anrilock brom., described, 301-302 Apparel, riding safety, 346 Asbestos fiber, drum brake service, 305 Assembled wheels, wheel design. 253-254. 255 Atom, electrical theory, 177 AttiOJde, riding safety, 351 Audio systems, accessory systems. 250-251 Autoignition. Su Detonation (auloignition) Automatic hydraulic valve lash adjusters. 45, 46 Axle nuts, wheel maintenance and service. 257

B

Backbone frame, 270, 271 Balancing

crnnksbaft, 58-59, 61 wheel maintenance and service. 262-263

Ball and roller bearings, 63, 78-79 Ball-peen hammer. 318, 319 Ball-ramp release. clutch release mechanisms, 105 Battery

discharge and charge. 189-190 lead-acid battery, 188-190 low-maintenance banery. 193 service and testing of. 190-192. 205, 222, 329, 339

367

370

Drive train (contd.) primary drive system, 98, 100-101

belt drive system. 101. 120-121 chain syStem, 100, 120 gear syStem., 98, 100, 120 service, 120-121

principles of operation, 96--98 gear ratio, 97 gear types. 96-97 power fl ow, 98 torque and rpm., 97-98

service, 120-124 clutch service, 121 final drive belt system., 123 final drive chain syStem., 123 final drive shaft system., 124 primary drive belt system. 120--121 primary drive chain system, 120 primary drive gear system, 120 transmission service, 122-123

transmission, 1 l(}""l 15 direct drive transmission. 111-112 dual-range transmission, 112-113 generally. 110 indirect drive traDsmission. 1l0--1I 1 service, 122-123 shift detents, 11 5 shift linkage, 113-115 shift mechanisms. 115

Drum brakes, 294--297. 305 Dry clutch, service. 121 Dual-range transmission, 112-113, 123 Dual-wall shock absorber design. 283--284 Dyke ring. two-stroke engine component, 75 Dynamic timing, service and testing. 207-208

E

Electrical systems. See Accessory systems; Lighting syStems; Safety systems; Warning systems

Electrical theory, 177-196 battery

lead-acid battcry. 188-190 lOw-maintenance battery, 193

current, 180--183 magnetism, 185-186 measurement, 183-185

Obm's law. 183-184 Wan's law. 184-185

principles of. 177-178 production of electricity. 186-188 service and testing. 193--196

ammeter. 194 ohmmeter. 195

Electrical theory (contd.) VOltage drop, 195-196 voltmeter. 193-194

terminology, 178 Electrical wiring. See Wiring Electric starting system, 125, 127-128 Electromagnetism, 18~ 187 Electronic fuel injection. 171-174 Electrons. electrical theory. 177-178 Emissions. 153--157

control of. 156-157 emission control systems. 154 EPA regulation, 154 generally. 153 sources of. 154--155

Emulsion damper. shock absorber design. 284

Index

Energy transfer magneto ignition system, 217-218. 220 Engine load. Su Load Engine moun~ 275. 276, 277 Engine performance factors. See Internal combustion

engine: perfonnance factors Environmental Protection Agency (EPA). 69. 154. 155.

174 Equa.lizer robes, 69 Evaporative emission control system, 154 Exhaust

residual gases, 20-21 two-make engine operation, 89-91

Exhaust gas analyzer, emissions and, 155, 156-157 Exhaust port, two-stroke engines, 73, 91 Exhaust stroke. four ·stroke engine operation. 31 Exhaust system

four.stroke engine, 69-70 two-stroke engine, 82-83. 84, 341

Exhaust Ultimate Power Valve (EXUP), 69 Exhaust valve. 43 Expansion chamber, exhaust system, 82-83. 84 Expansion rate. two-stroke engine formulas. 92 Externally grounded field generator, 235 External threads. 322 Eye protection, riding safety, 346

F

Feeler gauge. described. 13 Field coil teSts. 234 Files. 3 13 Final drive system, 115-119

belt drive system, ll8, 123 chain drive system, I 17-118. 123 drive train operation. power flow, 98, 99 generally, 115-ll7 service. 123-124 shaft drive system, 118-119, 124

=

Index

Finned cylinder, 72 rue extinguisher, 310 Fixed vennui carburetor. 1~167 Flat surface-to surface seals, 79 Flat-tip screwdriver. 312 Floating brake mounts, described, 302 Fluted sockets, 314 Flux lines, magnetism, 186 Foam. inhibitors, lubricants, 132 Footpegs, frame component. 276 Four-stroke engines, 28-70. See alsQ Internal combus­

tion engine; Tune-up and service (four-stroke engine); Two-stroke engines

bearings and bushings, 62-06 ball and roller bearings, 63 general service, 66 needl. bearings, 63, 64, 65 plain bearings, 65 tapered roller and thrust bearings, 65-66

cnnkcase, 6Hi2 =nksbaft, 57~1

balancing, 5~S9 connecting rods, 57-58 design, 57 general service. 5~1

oylinder(s), 54-57 described, 54-55 service.5S-57

oylinder heads, 36-41 described, 36-41 general service, 41

design of, 31-36 horizontally opposed multicylinderengines, 34 horizontally opposed rwin-cylinderengines, 34 in-line multicylinder engines, 34, 36 single-cylinder engines. 32 vertical twin engines, 33 V -four engines, 36 V -twin engines. 32, 34, 35

exhaust systems, 69-70 described, 69 service, 69-70

generally, 28-30 lubrication system. 134-138

described, 134-136 service and troubleshooting, 136-138, 140

operation of, ~31 pistoos,50-54

described, 5~53 service. 53--54

sealing devices, 67-69 tune-up and service, 327-336. See also Tune-up and

service (four-stroke engine) turbulence and, 24

Four-stroke engines (comd. ) two-stroke engine contrasted, 73 valve ttaiD, 42-50

automatic bydraulic valve lash adjusters, 45, 46 camshaft, 42~S general service, 49-50 rocker arms, 47 shims and buckets. 47 tappets and pushrods. 45 valve guides and seals, 49 valves, 47~8 valve springs, 48

Fractions, metric system conversions, 8 Frame, 269-277. See also Suspension

components. 272, 274-276 construction. 269 design, 269-272 maintenance and service, 276-277

Front-end steering bead, 274, 276. 277 Front fork, 289-291 Fuel(s). 152-153

additives to. 153 ignition system and, 212-213 octane and octane numbers, 152-153 oxygenaIed fuels, 153 quality of, 24

Fuel filter, 149-150 Fuel-level indication system, warning systems, 247 Fuelllnes, 150 Fuel pump, 149 Fuel screw adjustment, carburetor service, 168-169 Fuel system, 147-157. See also Carburetors

components of, 147- 152 air filter, 150-151 carburetor.151 fuel filter. 149-150 ruellines, 150 fuel pump. 149 fu.1 tank, 147, 149 intake manifold, 151- 152 petcoc:l::, 149

electronic fuel injection. 171-174 emissions. 153--157

oontrolot 156-157 emission conlrOl systems, 154 EPA reguJation, 154 generally. 1.53 sources of. 154-155

fuels , 152-153 service, 152 rurl>oclwging, 174-176

Fuel tank, 147. 149 Full stroke ratio, compression ratio, 19 Full-wave systems, ac charging systems, 226-227 Fuses, circuit. electrical theory, 182

37'

372

G

Gaskets, 67 Gas laws, 17 Gasoline. Su Fuel(s) Gear ratio. drive train operation, 97 Gear system, drive train, 98, 100. 120 Gear types, 96--97 Gen=

ac charging system, described. 228 de charging systems, 235-237

polarizing generators, 239 testing. 239

Ground, electrical theory, 182 Growler, generator testing. 239

H

Hacksaw, 313 Half·wave systems. 2~226 Hall effect transistoriz.ed controlled ignition system. 215 Hammers, 318--319 Handlebars, 274 Handling problems, troubleshooting of, 292-293. Su

alSQ Steering; Suspension Handtools. See Tools; entries untkr 1Itl1neS of spuific

lools Headlights, lighting systems. 242-244 Heat efficiency, efficient combustioD factors, 25 Heat range. 204. 212 Heat transfer principles. cooling system. 140 Helmet, riding safety, 346 Hemispherical cylinder head., 38, 40 High schools, training programs in. 3 High-tension magneto ignition system. 216-217, 220 Horizontally opposed multicylinder engines, 34 Horizontally opposed twin-cylinder engines. 34 Horns. warning systems, 248-249 Horsepower. 26--27 Hydraulic disk brakes, 298-301, 306--307 Hydraulic release, clutch release mechanisms, 106, 108 Hydraulic valve lash adjusters. See Automatic hydraulic

valve lash adjusters Hydrocarbons. Su Emissions Hypotbennia. riding safety. 350

Ignition coil, 201-202, 208 Ignition override system, 250 Ignition points, service and testing, 205--206

Ignition system, 197-220 components. 197-204

capacitor, 200-201 ignition coil, 201-202 secondary wiring. 202 spark plugs, 202-204 timing device, 197-200 voltage source. 197

emissions and, 155 factors affecting, 212-213 service and teSting, 205--212. 219-220

battery, 205 capacitor. 205 four-stroke engine, 329-330 ignition coils, 208 ignition points, 205--206 ignition timing. 2~208 point gap, 205 secondary wiring, 209 spark plugs. 209-212 two--stroke engine, 340

types of, 213-219 battery-assisted systems, 213-215 battery less systems. 215--219

Ignition timing. two--stroke engine. 89, 340-341 Indicated mean effective pressure (IMEP). 26 Indirect drive transmission, 1l~1l1 Induction, electrical theory. 187 Industrial Fastener lnstirute (IFI). 320 In-line multicylinder engines, 34. 36

Index

Instrument lighting, lighting systems, 245 Insulation breakdown test, ignition coil teSting, 208 Insulators. electrical theory, 178 Intake. two-stroke engine, 87-88 Intake manifold, fuel system component, 151-152 Intake pon, {Wo--stroke engine, 72, 80 Intake stroke, four-stroke engine. 30 Intake systems, two--stroke engine, 80-82 Intake valve. four-stroke engine, 43 Internal combustion engine, 17-27. See also Four-stroke

engines; Tune-up and service; Two-stroke engines abnormal combustion, 21-23

detonation, 21- 23 preigoition,21

combustion process, 18 efficient combustion factors . 25--27

crankshaft force, 26 cylinder pressure, 26 heat efficiency, 25 mechanical power, 26-27

engine design factors , 23-25 compression ratio. 23 engine load. 23 fuel quality, 24

Index

Internal combustion engine (concd.) ignition and. 212 state-of-tune, 24-25 turbulence, 24

performance factors , 18--21 air/fuel ratio, 20 bore and stroke, 20 compression ratio, 18--19 residual exhaust gases, 20-21 volumeaic efficiency, 19-20

physical laws, 17-18 gas laws, 17 thermodynamics, 17 working of, 18

Internal cooling, 1~142 Internally grounded field generator, 235 Internal tIrreads, 322 International Standards Organization (ISO), 6, 320

J

Jacketed cylinder, two-suoke engine. 72

K

Keystone piston ring, two-stroke engine. 75

L

Lacing, wheel maintenance and service, 258--260 Lead-acid banery. See Battery Leaded gasoline, 24. See also Fuel(s) Lever release. clutch release mechanisms, 106 Lighting systems, 242-245

headlights, 242-244 ~UtUnentlighting,245

stoplights, 244-245 taillights, 244 turn signals, 245

Liquid cooling system described, 142 service, 143-146 two-stroke engine, 85

Liquid sealer, 67 Load

circuit, elecaical theory, 182 engine design factors. 23 lubrication system functions. 130 tire selection, 265

Load test, batteries, 191-192,222 Looped scavenging. 89

Low-maintenance batteries, 193 L-ring, two-stroke engine, 75 Lubrication

four-stroke engines, bearings, 66 two-stroke engine

bearings, 79 service, 93

Lubrication system. 129-140. See also Oil four-stroke engines, 134-138

described, 134-136 service, 136-138

generally, 129 oil composition, 129-130 oil properties, 131-132 oil testing and classification, 133-134 purposes of, 130-131 troubleshooting, 140 two-stroke engines, 83, 138-139

described, 138 service, 139

M

Machine screws, 321-322 Magnetism, 185-186 Magneto ignition systems, 215-218, 220 Main bearing inspection, 338--339 Matter, electrical theory, 177 Means of control, electrical theory. 182 Measurement (electrical), 183-185

Ohm's law. 183-184 Watt's law, 184-185

Measurement systems. 5-16. See also Metric system historical overview of, 5-6 meaic conversions, 7-1 1 metric syStem, 6-7 tool use for, 11-16. See also Measurement tools

Measurement tools, 11-16. See also Tools dial indicator, 14-15 feeler gauge, 13 generally, II micrometer, 14 rulers, ]2 small hole gauge, 16 telescoping gauge, 15-16 vernier caliper, 12-13

Mechanical power, 26-27 Mechanical spark advance. timing device, 198 Mechanical voltage regulator, ac charging system,

229-230, 234 Metals compatibility, lubricants. 132 Metric system

conversions, 7-11

373

37.

Metric system (con.rd.) conversion tables. 9-10.11.252-253 described, 6-7 tool use for. 11-16

Micrometer, described. 14 Midgeley, lbomas. 24 Mineral-based oils. described. 129 Mixture enricher cold-starting system. 171 MotOrCycle industry, 1-4

growth in. I job opportunities in, 1-3 training programs for. 3-4

Motorcycle Safety FoundatioD Rider Course, 347 Mounting areas, frame component. 276 Mouton, Gabriel, 5 Mufflers, described, 69

N

Needle bearings, 63, 64. 65. 79 Nonsegregated atmospberic damper, shock absorber

design, 283 Nontbreaded fasteners, 324--325 Nuts, 322

o Octane and octane oumbers. 152-153 Offset wrist pin bores, 52 Ohmmeter. 195 Ohm's law, 183-184 Oil. Su also Lubricatioo system

composition of. 129-130 internal cooling. 1 ~ 141 properties of. 131-132 recommeodations

four-stroke engine, 137 ~sttokeengine,138

testing and classification of. 133-134 Oil filter, 1~137, 329 Oil forks. front fork. design, 289 Oil indicator system, 247-248 Oil injection service, 339 Oil passages, 136 Oil pressure, 138 Oil pumps

fOUNtroke engine, 134, 136. 137 two-stroke engine, 139

One-way valve, shock absorben, 283 O-rings,67 Overhead cams, 39, 43 Oxidative stability, lubricants. 132 Oxygenated fuels. described. 153

Index

p

Parallel circuit, electtical theory. 183 Pans manager. job opportunities and description, 2-3 Perlormance factors. Set Internal combustion engine:

performance factors Performance test, ignition coil testing, 208 Perimeter frame. 270, 273 Petcock, fuel system component, 149 Phillips screwdriver, 312 Phillips sockets, 314 Pboto-optic ignition system, troubleshooting. 220 Piston(s)

four-stroke engine. 5~54 two-strok.e eugine. 72. 73-75

Piston clearances, 94-95 Piston-pon intake system, 80 Piston rings

four-stroke engine. 52-53 two-stroke engine, 75

PistoD-to-connecting rod clearance, 74-75 Plain bearings, 65 Plate air restrictor cold-starting system. 171 Pliers, 316-318 Point gap. service and testing, 205 Polarizing generatorS. 239 Poppet valves, 47-48 Ports, two-stroke engines, 72-73 PostcOmbustion activity, 18 Pour point depressants, lubricants, 132 Power, 89 Power How. 98 Power stroke, 85 Preignition. abnormal combustion. 21 Premix.ing, two-stroke engine lubrication system, 139 Preride check, riding safety, 347 Pressure plates, 102 Pressurized segregated damper, shock absorber design,

284 Preventive maintenance, riding safety, 345-346 Primary drive starting system, 124-125, 126, 127 Primary drive system. 98, 100-101, 120-121. Su also

Drive train: primary drive system Punches, 315 Pushrods. 45

R

Rack-and-pinion release. clutch release mechanisms. 105-106

Railroad tracks, riding safety, 350. 351 Rain, riding safety. 350 Rake, steering geometry, 291-292

Index

Real-wheel swing ann, frame component. 275--276 Rear chain and sprocket service. 335, 342 Rear-wheel swing arm, 276, 277, 282 Rebound. swpension factors. 278-279 Rebuilding. general service, 41 Rectifier tests. ac charging system testing. 232 Reed valve intake system, two-stroke engines, 81 Regulator. Su Voltage regulator Reserve lighting units. safety systems. 250 Residual exhaust gases, 20-21 Resistance test. ignition coil testing, 208 Retaining rings, 324--325 Rican!o. H""". 24 Rich fuel mixtures. internal cooling, 141 Riding safety. 345-351

apparel, 346 attitude. 351 generally, 345 habits. 347 preventive maintenance, 345-346 riding conditions, 350-351 skills, 347-350

Rim repair. wheel maintenance and service, 258 Road surface, riding safety, 350 Rocker ann, valve train. 47 Rocker arm release, clutch release mechanisms, 105 Rotary valve intake system, 81-82 ROlating surface seals, 67, 79-80 Rpm. drive train operation, 97-98 Rubber-mounted frame, 272, 274 Rulers. described, 12

s Safety inspection. See also Riding safety

four-stroke engine. 335-336 two-stroke engine, 344

Safety rules (shop). 308-309, 310 Safety systems, 249-250

ignition override system, 250 reserve lighting units. 250 sensors, 250 starter override system, 249-250

Screwdriver, 312 Screw release. clutcb release mechanisms, 106 Sealing devices. four.stroke engine, 67-69 Seals and sealell

crankcases. 62 two-stroke engine, 79-80

Secondary wiring. 202. 209 Self-induction, production of electricity, 188 Semiautomatic clutch., 106-107, 109. 121 Semiconductors, electrical theory. 178

Semispberical combustion chamber, 39, 41 Sensors, safety systems, 250

375

Series circuit. electrical theory, 182-183 Service manager. job opportunities and description, 3 Service 'Writer. job opportunities and description, 2 Shaft drive system, final drive system, 118-119. 124 Shallow hemispherical chamber. 39 Shift detents, transmission. 115 Shift linkage, transmission, 11~115 Shift mechanisms, transmission, 115 Shims, valve train, 47 Shock absorbers, 282-286 co~on,284-285

design. 283-284 gener.lUy, 282-283 maintenance and service. 277, 285-286 single-shock systems, 285

Shop safety rules, 308--309, 310 Side squisb combustion chamber. 38--39, 40 Silicon-controlled rectifier (SCR). 227 Siogle-cylinder engines. 32 Single-shock systems, 285, 287 Slide carburetor, 161-162, 17~171 Slotted spring pins, 324 Small hole gauge. 16 Society of Automotive Eogineers (SAE), 320. 323 Socket bandles, 314 Sockets, 31~314 Soft b.mun..-. 318. 319 Solid-state spark advance, 199-200 Solid-state voltage regulatoc. 230. 233 Sound systems, accessory systems, 250-251 Spark advance. ignition system and, 212 Spark plugs, 202-204

selection of, 93 service and testing, 209--212, 329. 340

Speedometers. 246 Speed ratings. tire selection, 265 Spinlock !bread. 324 Split rim wheels, wheel design, 254, 255 Spoke wheels. 255-257 Sprag clutch. 102 Spring-loaded balls, shock absorbers, 283 Springs, suspension component, 278--282 Spring washer, shock absorbers. 283 Sprung weight, suspension factors, 278 Squisb band, turbulence and., 24 Starter motors, 240-241 Starter override system, 249-250 Startiog system, 124-128

direct drive syStem, 125. 126 electric. 125. 127 primary drive system, 124-125. 126 service, 127-128

376

State-of-tune, engine design factors, 24-25 Static timing. service and testing, 206-207 Stater coDtinuity test, 232 Stator insulation test, 232 Steering, 291-293. See also Suspension

geometry of. 291-292 troubleshooting handling problems, 292-293

Steering stem, frame component, 275 Stoichiometric ratio, airlfuel ratio, 20 Stoplights, lighting syStems, 244-245 Storage. tire maintenance and repair, 268 Stroke. See Bore and stroke Sump systems, 134. 135 Suspension, 277-291. See also Frame

factors affecting. 278-281 front, 286-291. See also Steering

front fork design. 289--291 front fode troubleshooting and repair. 291 gener.atiy, 286, 288-289 telescopic damper, 289 telescopic front end., 289

gener.aUy, 277-278 rear, 282-286

shock absorbers, 282-286. Se~ also Shock ab­sorbers

springs. 282 swing arm. 282

Swing arm. See Rear-wheel swing arm Synchronization, carburetor service. 169--170 Synthetic-based oils, described, 129 SyStem wiring tests, ac cbarging system testing, 234

T

Taillights. lighting systems, 244 Tapered roller and thrust bearings, 65-66 Tappets, va1ve train, 45

Technician. job opportunities and description. 2 Technology, motorcycle iodusay and, 1 Telescopic damper, 289 Telescopic front end, 289, 290 Telescoping gauge, 15-16 Temperature gauges, 246-247 Test ride

tom-stroke engine, 336 two-stroke engine, 344

Tetraethyllead. 24 Thermal efficieocy, 25 Thermodynamics, 17 Threaded fasteners . 319--324 Thread repair, 325--326 1'hree-pbase systems. ac charging systems. 227-230

Throttle cable adjustment, carburetor service. 168 Tickler cold-staning system, 171 Timed ignition

tom-stroke engine. 31 two-stroke engine. 89

Timing device, 197-200, 206-208 Tires. 263--268. Stt also Wbeel(s)

inspection, 333. 343-344 maintenance and repair, 266-268 selection of, 2~266 tubeless tires. 263-264 tube tires. 264

Tools, 309-326. Stt Measurement tools fasteners. 319-325

nonthreaded fasteners, 324-325 threaded fasteners. 319-324 tIuead repair. 325-326

bandtools. 309-319 bencb vise, 309 chisels. 316 die grinder, 313 drill motors, 312-313 files, 313 hacksaw, 313 hammers. 318-319 hand impacts. 312 pliers. 316-318 punches, 315 screwdriver, 312 socket handles. 314 sockets, 313-314 rorque wrench, 311 wrenches. 314-315

Torque drive train operation, 97-98 force, 26. 27

Torque amplification chamber system. exhaust, 91 Torque converter, 107. 109, 121 Torque wreocb. 311 Trail, steering geometry, 291-292 Training programs. motorcycle industry, .3-4 T raosfer. two-stroke engine operation. 91 Transfer port, two-stroke engines, 73 Transistor-assisted contact (IAC) ignition system.

213-214, 219

Index

Transistor pointless ignition (JPI) system., 214-215, 219 Transmission, 11~115

direct drive transmission. 111-112 drive train operation. power flow, 98, 99 dual-range transmission, 112-113 generally. 110 indirect drive IrallSmission. 11~111 sennce, 122-123. 339

Index

Transmission (contd.) shift detents, 115 shift linkage, 113--115 shift mechanisms, 115

Tread pattern, tire selection, 265-266 Triple clamp assembly, frame component, 274 Truing, wheel maintenance and service, 260-262 Tubeless tires, 263--264, 267-268 Tube tires, 264 Tune-up and service (four-stroke engine), 327-336. Su

also Four-stroke engines air filter, 331-332 banery inspection, 329 brake adjusunent, 333 cable inspection, 333, 334 cam chain adjustment, 330 carburetor synchronization, 332 clutch adjustment, 333 compression check. 328 drive shaft, 335 gener.ally,327-328 ignition system, 329-330 oil and filter change, 329 rear chain and sprocket inspection, 335 safety inspection, 335-336 spark plug inspection, 329 test ride, 336 tire inspection, 333 valve adjustment, 330-331

Tune-up and service ([Wo-StrOke engine), 337-344. Su also Two-stroke engines

air filter, 340 battery inspection., 339 brake adjustment, 342-343 cable inspection, 343 clutch adjustment, 342 compression check, 338 drive shaft service, 344 exhaust system, 341 generally, 337-338 ignition system, 340 ignition timing, 340-341 main bearing inspection, 338-339 oil injection service, 339 rear drive chain and sprocket service, 342 safety inspection, 344 spark plug inspection, 340 test ride, 344 tire inspection, 343--344 transmission, 339

Turbocharging, described. 17~176 Turbulence. engine design factors, 24 Turn signals, lighting systems, 245 Twin-spar frame, 272

Two-stroke engines, 71-95. Su also Four-stroke en­gines; Internal combustion engine; Tune-up and service ([Wo-sttoke engine)

components of, 71-80 bearings, 78-79 connecting rods, 75-76 crankcase, 76-78 crankshaft, 76 cylinders and cylinder heads, 71-73 generally, 71 piston(s),73--75 piston rings, 75 seals, 79-80 wrist pins, 75

design, 85, 86 fonnulas, 92 lubrication system, 138-139

described, 138 service, 139

operation of, 85-91 compression., 88 exhaust, 89-91 generally, 85, 87 intake, 87-88 power, 89 timed ignition, 89 transfer, 91

service and adjustments, 93-95 air/fuel mixture and carburetor adjustments, 93 carbon deposits, 94 carburetor, 170-171 crankcase pressure testing, 93 lubrication, 93 piston clearances, 94-95 spark plug selection, 93

syStems, 80-85 cooling systems, 85 exhaust system, 82-83 intake systems, 8O-S2 lubrication system, 83

3n

tune-up and service, 337-344. S~~ aLsQ Tune-up and service (two-stroke engine)

turbulence and, 24

u Underbone frame, 270, 272 Unified brake systems. 304 Uniform bearing stress (UBS) bolt, 323-324 Unloaded test, batteries. 191 Unspruog weight, suspension factors, 278

378

v Vacuumcarouretor, 162-166, 171 Vacuum spark advance, timing device, 198-199 Valve(s), engine components, 47-48. See also Valve

train Valve adjustment, 330-331 Valve guides and seals, valve train, 49 Valve lash adjusters. See Automatic bydraulic valve lash

adjusters Valve overlap, 31, 142 Valve seats, interference fit, cylinder heads, 36 Valve springs, engine components, 48 Valve train, 42-50

automatic hydraulic valve lash adjusters. 45, 46 camshaft, 42-45 rocker arms, 47 service, 49-50 shims and buckets. 47 tappets and pushrods, 45 valve guides and seals, 49 valves, 47--48 valve springs, 48

Variable ratio clutch. 102. 104 Variable venturi carburetor (slide carburetor), 161-162 Vegetable·based oils, 130 Verniercaliper.12-13 Vertical twin engines. four-stroke engine design, 33 V-four engines. four-stroke engine design, 36 Viscosity, 132. 133-134 Vixen Iiles, 313 Vocational schools, training programs in, 4 Voltage drop, testing for, 195-196 Voltage output. ac charging system testing. 230 Voltage regulator

ac charging system. 229-230, 233-234 de charging system, 237-238. 239 terminology. 225

Voltage source, ignition system component, 197 Voltmeter, 193-194 Volts, electrical theory, 181 Volumetric efficiency, 19--20 V -twin engines, 32, 34, 35

w Warning systems, 246-249

battery condition indicator, 248 brake fluid indicator, 248 fuel-level indication system, 247 horns, 248-249 oil indicator system, 247-248 speedometers, 246 temperature gauges, 246-247

Washers, 323 Wan. James, 184 Watt's law, electrical measurement, 184-185 Weather, riding safety, 350 Weslake, Harry, 24 Wet clutch, service, 121 Wet pavement, riding safety, 350 Wheel(s), 252-263. See also Tires

components, 252 design, 252-256

assembled wheels, 253-254, 255 cast wheels. 253 split rim wheels, 254, 255 spoke wheels, 2!i.5-256

maintenance and service, 256--263 axle nuts, 257 balancing, 262-263 rim repair, 258 spokes, 256-257 truing.260-262 wbeel bearings. 257, 258 wbeeIlacing, 258--260

Index

Wheel bearings, maintenance and service, 257, 258 Wheel lacing. maintenance and service, 258-260 Wiring

accessory systems, 251 schematic of system, 179 secondary wiring, 202, 209 system wiring tests

ac charging system testing, 234 dc charging system testing, 240

Wrenches, 314-315 , Wrist pin. two-stroke engine component, 75 Wrist pin bores. pistons, four-stroke engine components,

52