DOCUMENT RESUME ED 319 915 CE 054 857 AUTHOR Baugus, Mickey; Fulkerson, Dan, Ed. TITLE Motorcycle Mechanic. Teacher Edition. INSTITUTION Hid-America Vocational Curriculum Consortium, Stillwater, Okla. PUB DATE 88 NOTE 892p. AVAILABLE FROM Mid-America Vocational Curriculum Ccnsortium, 1500 West Seventh Avenue, Stillwater, OK 74074 (order no. 100462, $23.00). PUB TYPE Guides - Classroom Use - Guides (For Teachers) (052) EDRS PRICE MF06 Plus Postage. PC Not Available from EDRS. DESCRIPTORS Auto Mechanics; *Maintenance; Metric System; *Motor Vehicles; Postsecondary Education; Secondary Education; *Small Engine Mechanics; Vocational Education IDENTIFIERS *Motorcycles ABSTRACT These teacher's materials are for a 19-unit competency-based course on entry-level motorcycle mechanics at the secondary and postsecondary levels. The 19 units are: (1) introduction to motorcycle repair; (2) general safety; (3) tools and equipment; (4) metric measurements; (5) fasteners; (6) service department operations; (7) motorcycle engines; (8) battery and electrical service; (9) carburetion and fuel systems; (10) wheels and tires; (11) steering and suspension; (12) brakes; (13) clutches; (14) starting systems; (15) basic ignition tune-up; (16) basic engine tune-up; (17) basic' chassis tune-up; (18) assembly and predelivery; and (19) one-cylinuer engine top-end service. The first section is designed to show teachers how to use the materials and includes an explanation of instructional elements, an instructional task analysis for each unit; a list of tools, equipment, and materials; and a list of 25 references. The instructional elements for the units include objectives, suggested activities, information sheets, transparency masters, assignment sheets, answers to assigner.` sheets, job sheets, tests, and test answers. Some elements, such as tne information sheets, include photographs, diagrams, and line drawings. (CML) ***********************************A*********A**********2******g******* Reproductions supplied by EDRS are the best that can be made from the original document. *****A**********A****************A*****x******************************* r U. DEPARTMENT OF EDUCATION Orfce Educational Research and improvement ED `PERMISSION TO REPRODUCE THIS TIONAL RESOURCES INFORMATION CENTER (ERIC) MATERIAL IN MICROFICHE ONLY and document has been reproduced as HAS BEEN GRANTED BY received from the person or organization coginating it. 0 Minot changes have been made to improve Ap~A., reproduction quairty Pomts 01 *nevi or opinions stated m tntsclocu- ment do rot necessary represent official OE RI 0054,05 or policy TO THE EDUCATIONAL RESOURCES INFORMATION CENTER (ERIC)." 1 a MID-AMERICA fry VOCATIONAL 0 0 CURRICULUM CONSORTIUM BEST COPY AVAILABLE North Dakota South Dakota Iowa Nebraska Colorado Kansas Missouri Oklahoma Arkansas Texas Louisiana 3 MOTORCYCLE MECHANIC Written by Mickey Baugus Edited by Dan Fulkerson Developed by The Mid-America Vocational Curriculum Consortium, Inc. Board of Directors Harley Schlichting, Missouri, Chairman Larry Lyngstad, South Dakota, Vice Chairman Ron Mehrer, North Dakota, Parliamentarian James Dasher, Arkansas Bob WI !moth, Colorado John Van Ast, Iowa Les Abel, Kansas David Poston, Louisiana Ann Masters, Nebraska Joyce Sawatsky, Okahoma Robert Patterson, Texas 4 CN100462 88-005028 c) 1988 by the Mid-America Vocational Curriculum Consortium, Inc. All rights reserved. No part of this book may be reproduced in any form or by any means without written permission from the publisher. Printed in the United States of America by the Oklahoma State Department of Vocational-Technical Education Stillwater, OK 74074 Mid-America Vocational Curriculum Consortium, Inc. 1500 West Seventh Stillwater, Oklahoma 74074-4364 5 MOTORCYCLE MECHANIC TABLE OF CONTENTS Unit I: Introduction to Motorcycle Repair 1 Unit II: General Safety 33 Took and Equipment Unit III: 79 Unit IV: Metric Measurements 111 Fasteners Unit V: 173 Unit VI: Service Department Operations 237 Unit VII: Motorcycle Engines 271 Unit VIII: Battery and Electrical Service 313 Carburetion and Fuel Systems Unit IX: 379 Unit X: Wheels and Tires 437 Unit XI: Steering and Suspension 533 Unit XII: Brakes 593 Clutches Unit XIII: 637 Starting Systems Unit XIV: 669 Basic Ignition Tune-Up Unit XV: 703 Unit XVI: Basic Engine Tune-Up 733 Unit XVII: Basic Chassis Tune-Up 819 Unit XVIII: Assembly and Pre-Delivery 847 Unit XIX: One-Cylinder Engine Top-End Service 885 iii 6 FOREWORD Should Motorcycle Mechanic become an award winning book, it wouldn't surprise us. You see, Mickey Baugus, the writer, is used to awards and impressive ones at that! Miclzey's motorcycle repair program at Central Vo-Tech in Drumright, Oklahoma, won the Secretary of Education's award for being the outstanding vocational program in America! The award, from the office of then Secretary of Education, the honorable T.H. Bell, was presented to Mickey at an all-school advisory comm!itee meeting in 1983. The Secretary of Education's Award brought national attention. In 1984, Mr. Tetsuo Chino, President of American Honda, visited Central Area Vo-Tech to personally congra...late Mickey Baugus, and to announce Honda's donation of six million dollars worth of motorcycles and equipment to American vocational education programs, a milestone in vo-tech history. We feel that Mickey's award winning abilities are evidenced in the pages of this text. The entry- level skills presented here follow the same guidelines that Mickey emphasizes in Central Vo- Tech's motorcycle repair program. They are the same entry-level skills endorsed by Mickey's advisory committee, and for all these reasons, we feel that Motorcycle Mechanic will provide a utilitarian curricululm for motorcycle repair programs everywhere and turn them into win- ners. Harley Schlichting, Chairman Board of Directors Mid-America Vocational Curriculum Consortium v PREFACE When we speak of "entry-level" skills in motorcycle repair, we are talking about job getting skills. These skills include tire and wheel service, assembly and set-up service, and battery service, and a reminder that an entry-level technician will probably have to sweep the parking lot every now and then. As motorcycle dealerships expand into all terrain vehicles, lawn and garden equipment, and pom 'red watercraft, the opportunities for motorcycle mechanics takes on new horizons. Motorcycle Mechanic offers the basics that a beginner needs te get a job ak.ag with the solid foundation required to turn a job into a career. We might remind you also that Motorcycle Mechanic is part of MAVCC's impressive small engine repair series which includes Small Engine Repair: Two-Stroke and Four-Stroke Cycle, Chain Saw Repair, Outdoor Power Equipment Repair, Outboard Repair, and Snowmobile Repair. The books are all competency-based, and have become classroom favorites across the country. Keep MAVCC in mind for outstanding Program materials. Greg Pierce Executive Director Mid-America Vocational Curriculum Consortium ACKNOWLEDGEMENTS The Resource Committee which planned and approved Motorcycle Mechanic was comprised of a choice selection of outstanding motorcycle repair instructors and an impressive group of national service representatives from the well-known major motorcycle manufacturers. The group also included owners of motorcycle dealerships, and we feel the expertise of that impressive committee helped make the text an outstanding one. To the Resource Committee, we extend a special thank you: Mike Emberty Fort Collins Cycle Center, Fort Collins, Colorado Vocational Curriculum Development and Research Center, Kenneth Powers Natchitoches, Louisiana Al Goslee Southeast Community College, Lincoln, Nebraska John Shedd Holmes High School, San Antonio, Texas Indian Capital Area Vo-Tech School, Sallisaw, Oklahoma Randy Lowe Jerry Johnson Suzuki Motors, Dallas, Texas American Honda Motor Company, Gardena, California Lyle Sweeter Kevin Hartley American Honda Motor Company, Irving, Texas Kawasaki Motors Corporation, U.S.A., Irvine, California Ken Lizotte Norm McDonald K & N Motorcycles, Tulsa, Oklahoma Mickey Saugus Central Area Vo-Tech School, Drumright, Oklahoma Another special thank you goes to Dennis Hendrix of Yamaha, and to Donald Church and Ken Lizotte of Kawasaki for permission to reprint certain graphic materials that serve to enhance this text. And for their special interest, another vote of thanks goes to Kevin Hartley from the Honda Training Center in Dallas, and to Mike Baugus who contributed time to assist with pho- tographs. We thank the project editor, Dan Fulkerson, for doubling as photograher for the project, and the writer, Mickey Baugus, who also served as a valuable member of the Resource Committee. Many of the photographs for the text were made in the motorcycle repair shop at Central Area Vo-Tech in Drumright, Oklahoma. To the many students who helped with many of the photo graphs, a special thank you. And the same holds true for Norm and Lucy McDonald of K & N Motorcycles in Tulsa. They and their staff helped significantly with many of the photographs, and we thank them for their hospitality. The text was phototypeset by Leslie Mathis of the Graphics Department at Oklahoma State VoTech, and the text was printed at the print shop of the Oklahoma State Department of Voca- tional-Technical Education. To Graphics and Print Shop personnel, a thank you for a job well done. ix 9 USE OF THIS PUBLICATION Instructional Units !,:otorcycle Mechanic contains nineteen units. Each instructional unit includes some or all of the basic components of a unit of instruction; performance objectives, suggested activities for teachers and students, information sheets, assignment sheets, job sheets, visual aids, tests, and answers to the tests. Units are planned for more than one lesson or claSs period of instruction. Careful study of each instructional unit by the teacher will help to determine: The amount of material that can be covered in each class period A. The skills which must be demonstrated B. Supplies needed 1. Equipment needed 2. Amount of practice needed 3. Amount of class time needed for demonstrations 4. Supplementary materials such as pamphlets or filmstrips that must be ordered C. Resource people who must be contacted D. Objectives fibEach unit of instruction is based on performance objectives. These objectives state the goals of the course, thus providing a sense of direction and accomplishment for the student. Performance objectives are stated in two forms: unit objectives, stating the subject matter to be covered in a unit of instruction; and specific objectives, stating the student performance necessary to reach the unit objective. Since the objectives of the unit provide direction for the teaching-learning process, it is nd students to have a common understanding of the intent of the important for the teaches objectives. A limited nurr,,,a of performance terms have been used in the objectives for this curriculum to assist in promoting the effectiveness of the communication among all individ- uals using the materials. Reading of the objectives by the student should be followed by a class discussion to answer any questions concerning performance requirements for each instructional unit. Teachers should feel free to add objectives which will fit the material to the needs of the stu- dents and community. When teachers add objectives, tht. should remember to supply the needed information, assignment and/or job sheets, and criterion tests.