Motorcycle Repairing

Vinay Lal
Copyright © 2010 Vinay Lal. All rights reserved.
No part of this publication may be reproduced or transmitted in any form or by any means,
electronic or mechanical, including photocopy, recording, or any information storage and
retrieval system, without permission in writing from the author.
I dedicate this book with great respect and love to my family. The family support and motivation are the
source of my energy to write this book. I cannot imagine my career without the loving family. I am
grateful to the colleges and business organizations to provide me the resources to advance in career.
Contents
Acknowledgement:..........................................................................................................................................5
Introduction......................................................................................................................................................6
Motorcycle Basics............................................................................................................................................6
Basic function..............................................................................................................................................6
Major Parts of the Motorcycle:........................................................................................................................7
Power generation parts:...........................................................................................................................7
Transmission Parts:..................................................................................................................................7
Other Parts:...............................................................................................................................................8
Power Generation parts are as follows:.......................................................................................................8
Motorcycle maintenance:.............................................................................................................................9
Motorcycle Maintenance Requirements:.....................................................................................................9
Maintenance...............................................................................................................................................11
Scheduled or Preventive Maintenance..................................................................................................11
Breakdown Maintenance.......................................................................................................................12
Optimum maintenance...........................................................................................................................13
Observations and Estimation:....................................................................................................................14
Analysis of the problems:......................................................................................................................14
Rough estimation...................................................................................................................................15
Common problem symptoms:................................................................................................................15
Critical problem symptoms....................................................................................................................16
Estimation:.................................................................................................................................................17
Maintenance Execution:............................................................................................................................18
Prerequisites and tool requirements:.....................................................................................................18
Maintenance Analysis:...............................................................................................................................20
Maintenance Performance:........................................................................................................................20
Maintenance results:..................................................................................................................................20
Conclusion..................................................................................................................................................21
Acknowledgement:
This book introduces the popular automobile repairing norms in two and three-wheeler automobile
garages. Frequent visits to the engineering workshops and automobile stores were great help to develop
this book.
I express sincere thanks to Chief Mechanic of the Nataraj Garage, Mumbai Naka, Nasik, Maharashtra,
India to provide necessary support and guidance to explore troubleshooting methods of scooters, motor
cycles, mopeds, and geared two wheelers. Mr. Anees of the Anees garage provided the required resources
to study the common trouble shooting procedures of two wheelers.
I remember the time that I have spent for preventive and break down maintenance of my “Bajaj Spirit“
scooter. It motivates me to learn the art of automobile repairing. I am thankful to all my friends, relatives,
and colleagues to guide for motorcycles in the Indian market. One of the most popular motorcycle brand
“Hero Honda” is the inspiration to write this book.
I had discussions for with many automobile-repairing professionals about latest methods of the
motorcycle maintenance. I have seen the economic class motorcycles are mostly operated on the roads at
40 KMPH speed. The rough use and poor maintenance of automobiles owners is the only cause of the
under performing vehicles.
I have seen many professionals facing motorcycle troubles in the morning and evening hours. This book
is an attempt to help those professionals. Preventive and schedules maintenance of the motorcycles can
help reduce the pain of such professionals. I do understand the main cause of motorcycle breakdown is
the unavailability of resources and ignorance about the preventive maintenance.
Introduction
The following section provides basics of motorcycle components, its operation, and the tools required for
motorcycle maintenance. This section is intended for novice motorcycle owners who are eager to learn
the basic troubleshooting and preventive maintenance of their motorcycles.
Motorcycle Basics
Motorcycle is a basic mode of travel for majority of population in India. Most of the college students,
working professionals, teenagers, and middle-class people utilize motorcycles in daily routines.
Economic models, cost effect mileage, and low maintenance cost of the motorcycle are feasible in India,
a developing country.

Figure 1.0 Snap shot of 100cc economic class motorcycle

Basic function
Basically, motorcycle is a power transferring machine. It converts the chemical energy of petrol to the
kinetic energy. In the simple words, the motorcycle has a engine (power unit), power transfer mechanism
(transmission and gear box) and wheels to transfer the energy to kinetic motion of the motorcycle.

The figure 1.1 shows the basic functionality of a motorcycle

Chemical energy of The gear box and The rear wheel of

the petrol is chain transmission the motorcycle rubs
converted to the transfer the rotational against the road
rotational motion in motion of the engine and moves the
engine gears to the rear motorcycle
wheel
Figure 1.2 Motorcycle Snapshot

Major Parts of the Motorcycle:

The major parts of the motorcycle are classified according to power generation and transmission.

Power generation parts:

 Tank
 Petrol Tap
 Carburetor
 Block, Piston (energy conversion unit) and its lubrication system

Transmission Parts:
 Crank shaft and clutch
 Gear box and transmission unit
 Handle, shock absorbers, brakes, wheels, and electrical system
The figure 1.3 Motorcycle parts

Other Parts:
Parts required for the motorcycle control:
 Gear shifting lever
 Clutch
 Brakes assembly of the wheels
 Choke assembly.

Additional parts required for smooth operation of the motorcycle:

 Headlight
 Side indicators
 Brake light
 Speedometer
 Seat
 Footrest
 Tail lamp

These parts are required for smooth operation of the motorcycle. And other parts improve the aesthetic
aspect of the motorcycle. These parts are not necessary for basic operation of the motorcycle.

Power Generation parts are as follows:

Fuel Tank:
This part of the motorcycle is crucial, it stores the fuel required for the power generation in the
motorcycle. The tank is in the front section of the motorcycle. Typically, a motorcycle tank stores up to
8-10 liter of fuel (petrol). The tank is airtight and water proof to avoid loss of fuel quantity and quality.
The fuel regulation tap is located at the bottom of the tank to easy supply of fuel to the engine.

Petrol flow regulations tap:

The petrol regulation flow tap is useful to control the flow of fuel in the engine. The tap has two
indications for the minimum level of the fuel in the tank. It has to modes – normal and reserve. Reserve
mode denotes minimum quantity of fuel in the tank, and it is indication for refueling. Normal mode
indicates ample quantity of fuel in the tank.
Carburetor:
This part mixes the fuel that comes from tank with the correct ratio of the air. This mixture is sent to the
block--piston unit where chemical energy of the fuel converts to the reciprocating motion of the piston.
The carburetor also acts as the controlling mechanism for the torque generation of engine.

Block - Piston (energy conversion unit) and its lubrication system:

The Block and Piston are the heart of the motorcycle. The chemical energy of fuel converts to the
mechanical energy of the piston. The ignition of fuel in the block generates the hot gases. The hot gases
expand and push the piston. Four stroke motorcycles have in built lubrication system for the block unit to
increase its life against the wear and tear. This lubrication is done using the lubrication oil in the engine
or using a separate oil pump.

Motorcycle maintenance:
Motorcycle is a tough machine and does not require much maintenance. Its most common spares are
cheap and easily available. Well-planned motorcycle maintenance can lead to trouble free operation of
the motorcycles. Regular servicing of the motorcycle with oil change, parts replacement at regular
intervals, and greasing of various parts leads to increase in productive life of the motorcycle.

Motorcycle Maintenance Requirements:

Motorcycle maintenance requires tools and spare parts. Normally, you get a tool kit along with s new
motorcycle. It is mostly useful for motorcycle maintenance at a road site or minor maintenance at home.

Figure: 1.4 Tools

Tools List
 Ring and Fix spanners
 Workshop apron
 Pliers
 Screwdriver Set
 Electrical Cables
  Spark plug spanner
 Wheel Puncher kit
 Box spanner kit

Common spares:
 Clutch or Gear cables
 Head light, side indicator, tail, and lamp bulbs
 Spark plug
 Gear box oil 20/40W
 Brake shoes
 Wheel air tubes

The above spares are easily available at two-wheeler automobiles spare parts shops. Normally
motorcycles are manufactured for the economic use. Few motorcycles are manufactured for sports use in
extreme physical conditions.

Part list of 100 cc Motorcycle Bajaj Make

 Front and Rear tyres
 Tubes
 Brake shoes
 Shock absorbers
 Brake assembly

Motorcycle Body parts:

 Fiber body parts
 Chassis
 Chain cover
 Seat
 Petrol tank
 Steering fork and bearing assembly
 Brake and clutch levers and cables

Power transmission parts:

 Block piston assembly
 gear box
 Clutch assembly
 Chain and chain sprocket assembly
Maintenance
Maintenance of everything in this world is necessary— bicycle, house, television, camera, body, and hair
etc. Maintenance increases the life of the entity – your motorcycle is also a machine, and it requires
maintenance. For example— periodic change of the brake shoes of the motorcycle increases its life and
reduces the risk of accident. Maintenance is an art and requires year of experience for a good fix. Few
engineers have mastered the art to manage their precious machines. There are some technicians who
operate garages on the basis their experience. You can easily locate these trained technicians in your
locality.

You can plan your motorcycle maintenance and avoid frustrating faulty motorcycle situations. This saves
your money and precious time. Many people have different point of views for maintenance. They take
motorcycles to garages only after a breakdown. A breakdown indicates a series of problems. As a result,
many parts of motorcycle are located near the defective part of the motorcycle are affected. More
damage, more repairing, more cost -- only less motorcycle life.

For example – a 100CC motorcycle of Hero Honda brand has a little problem in the lubrication oil pump.
The pump stops working. The motorcycle sill operates, the piston--block unit suffers major wear and tear
in absence of the lubrication oil. One day the motorcycle stops to work. The repairing charges were
Rs.4000 (whole piston-block unit replacement). Preventive maintenance of the lubrication oil pump could
have saved Rs.3900. You can figure out, the cause and the impact in the scenario.

Scheduled or Preventive Maintenance

Preventive maintenance is mostly neglected in case of motorcycles and the motorcycle owners have to
face the consequences. Normally, people think about using the motorcycles until the breakdown occurs.
Maintenance with schedule preventives problems and saves your precious time.

Scheduled maintenance is implemented in steps. There are proper observations, discussions, and planning
sessions of the maintenance process. The technicians, engineers or the motorcycle owners note down the
observations. These observations are discussed with the motorcycle owner. Considering the cost, time,
feasibility, and urgency of the repair, the maintenance is planned. For example, the front wheel of the
motorcycle is noisy. It can indicate faulty ball bearing. The garage technician plans the repair at suitable
time. This faulty bearing can lead to an accident on the road. The preventive maintenance could have
saved precious life of driver and pillion. We will not consider the cost aspect.

Observations
for the Technician Fix done, cost
motorcycle fixes the plan saving in time
owner and and money
technicians.
Fig 1.6 Preventive maintenance process

Sr. Advance observation of problem Possible preventive fix

no.
1 Front wheel noisy
2 Rear brake noisy
3 Less mileage
4 Shock absorbers noisy
Check the front wheel bearings, brake shoes, and mud
guard.
Rear wheel brake drum faulty
Carburetor setting is faulty
The springs in the shock absorbers have lost the elastic
 property
5 Speedo meter needle shows The gears in the wheel that transmit the power to the
vibration speedometer are worn out
6 The brake shoes of rear wheel need The brake drum is damaged, needs replacement
frequent replacement
7 Noise when brake is applied Replace the brake shoes to avoid damage to the brake
drum
8 Starting problem The spark plug needs replacement
9 Bad pickup The clutch plates requires replacement
10 Bad balance The tyres are worn out

Table: 1.1 Preventive maintenance of motorcycle parts:

Breakdown Maintenance
Break down maintenance is an extreme state. The motorcycle is allowed to suffer up to extreme limit and
ultimately, it stops working. Majority of the economic motorcycles are fixed under breakdown
maintenance condition.

For example—the front shock absorbers of the motorcycle are not operating properly. There is little oil
leakage near the right shock absorber. The motorcycle owner neglects the condition of the shock absorber
and continuous usage creates more damage to shock absorbers and one day the shock absorber breaks
causing a road accident. The owner and motorcycle suffer major damages. The owner suffers hand
fracture and shoulder dislocation. The motorcycle’s head light assembly, handle, and wheel are majorly
damaged. The maintenance required total replacement of the affected parts. Mostly breakdown
maintenance is caused by—rash driving, road mishaps, and maintenance negligence.

Most common forms of break down of motorcycles affects these parts viz. tyres, tubes, headlight, side
indicators, clutch cables, block-piston assembly, damage to the shock absorbers, and wheel rings etc.
Figure 1.7 accident of motorcycle

Sr. Break down maintenance Affected part

no.
1 Brake failure Brake drum, brake lever
2 Piston cease Connecting rod, block, and piston
3 Tyre burst Tyre, tube
4 Over heating of the engine Engine oil replacement
5 The transmission chain breaks The chain and gears

Table: 1.2 Breakdown maintenance and affected parts

Optimum maintenance
Optimum maintenance is one step ahead of preventive maintenance. The parts of motorcycle are studied
for any irregularities. The motorcycle may be working fine but certain parts of the motorcycle require
maintenance like gear box lubrication oil, tires, clutch cables, and clutch plates etc. Optimum
maintenance improves the performance of the motorcycle.
Optimum maintenance is necessity of highly reliable system like brake mechanism in the motorcycle. If
the brake operation fails, the motorcycle will not work properly. The brake assembly of the motorcycle
operates on highly reliability factor.
For example, the motorcycle operates almost properly with misalignment of the wheels at lower speeds.
At higher speeds misalignment of wheel rings create vibrations and motorcycle does not operate properly.
This type of maintenance is implemented for optimum operation of the motorcycle systems.
Optimum maintenance is not very popular is motorcycle as the users are from middle class. The
motorcycle owners mostly prefer breakdown maintenance.
Educated and cautious motorcycle owners prefer optimum maintenance. Optimum maintenance is carried
out for the following motorcycle parts:

1. Power transmission assembly- Motorcycle mileage improvement

2. Gear box bearing replacement – To improve power transfer efficiency of the motorcycle
 3. Carburetor tuning - To improve mileage of the motorcycle
4. Connecting rod change in crank shaft assembly - To improve the performance of the block
piston unit.
5. Replacement of the engine and gear box packing set- To prevent any leakage of the block piston
using and oil leakage from the gear box.
6. Replacement of the electricity cables of the motorcycle – To improve the electricity flow in the
electrical system of the motorcycle in the old units.
7. Replacement of the spark plug for the engine - To improve the reliability factor for old
motorcycle units.
8. Repainting of the motorcycle unit- - To increase the life of metallic parts

Sr. Preventive Breakdown maintenance Optimum Maintenance

no. maintenance
1 Cost saving No cost saving Cost saving
2 Not necessary Necessary Not necessary
3 Avoids accident Do not avoid accidents Avoids accidents
4 Cheap Costly Cheap
5 Planned Not planned Planned

Table 1.3: Comparison of preventive, breakdown, and optimum maintenance

Observations and Estimation:
Observations are important in the motorcycle maintenance. Observations help to identify the problems
and sequentially create plan of action. Observations have many indications viz. noise, abnormal
appearance, functional problems, and vibrations at higher operational speed. We can make a checklist of
the observations of maintenance as follows:

General checklist for observation:

 Motorcycle starts and stops properly

 Abnormal noise at motorcycle operation and at rest
 Broken parts using visual observation
 Head, brake lights and side indicators operations
 Tyres are inflated and not worn out
 Brakes, gears, clutch, and accelerator work properly

Analysis of the problems:

The motorcycle maintenance observations are required for analysis of the problems. These observations
are taken as basis for the analysis. Consider the case of noisy rear front wheel of a motorcycle. Observe
the wheel properly. Slow movement of the wheel creates noise and fast movement increases noise.
Observe the wheel contact with the mudguard. It can be a case of loose nut and bolts of the mud guard. In
this example the analysis is done based on the physical observations.

The analysis is required to plan the maintenance. In the above example maintenance plan is made for the
repair. The mudguard is examined for any breakage or deformity due to lose bolt. In case of deformity,
the mudguard is welded to improve the quality of repair. The nut bolt is tightened using the correct fix
spanners. Hence analysis is a crucial part of maintenance.

Opening the motorcycle assemblies is crucial process. You are required to identify the position and
condition of parts of the motorcycle. You should be careful not to damage any parts while opening the
parts. Use quality tools to open the assembly of the affected part. The observations while opening the
parts gives clues to preventive and optimum maintenance of the motorcycle.

Once the motorcycle defective assembly is opened, a maintenance plan can be created as follows:

 Cleaning the parts

 Budget allocation and planning the defective parts
 Purchasing the parts to replace
 Preprocessing the assembly parts by applying various seals
 Physical assembly of the parts
 Testing at the various stages of assembly
 Final testing after the complete assembly of the parts

The maintenance type is decided in consultation with the motorcycle owner. According to the budget and
requirement (temporary or permanent) actions are taken for the maintenance. E.g., puncture tyre may
require tube change for permanent fix, for temporary fix an old tube. For a new tyre puncture fix is
temporary and required fix.

Based on the observations, analysis, planning, and the maintenance type an estimate of the maintenance
is created with reference to the financial conditions. This estimate is sent to the client for approval and
thus the observations and estimate of the repair is executed.
Rough estimation
Observations are carried out using the predefined checklist. The checklist is standardized to ease the
observations procedure. Following is a sample checklist:

 Visual inspection for any broken parts of the motorcycle

 Start the motorcycle and observer any abnormal noise
 Engage the gears in standing position by manually rotating the rear wheel
 Drive motorcycle slowly and observe for any deformities or abnormal behavior
 Vary motorcycle speed and observe for any abnormal noise
 Stop the motorcycle and observe for any oil leakage or loose parts

Use the above observations to create an analysis report. This report addresses the general problems in the
motorcycle operation. The analysis report is based on parameters like time, performance at variable
speed, noise observations in engine unit, oil leakage, ease of operation, and fuel consumption.

Once the analysis report is complete, the motorcycle is opened carefully with close observation of any
damaged parts. The motorcycle repair is planned after opening the motorcycle. A formal financial
estimate of the required spare parts, the labor cost and total cost of the repair fix.

The repair can be temporary or permanent term based on the criticality of the malfunctioning part. E.g.,
Block piston replacement is the case of long-term repair and clutch plate change is short term repair.

Once the analysis of the repair is complete the estimate is given to the motorcycle owner for the
approval.
The typical observation, analysis and estimation process takes about 1-2 days. Most of the motorcycle
repair completes within the 1-3 days. Original parts supplied from the manufacturers should be used for
the repair.

Common problem symptoms:

Most common problems of motorcycle are easily identified. The problems have symptoms that are
indication of specific problems. Motorcycle mechanics have mastered the art of identification of the
symptoms. You can also use the following symptoms to identify the common problems:

1. Motorcycle starting problem: Does start immediately and stops after few seconds. Spark plug not
clean, or petrol supply is inadequate. Clean the spark plug and use choke to start the motorcycle.
2. Gear change problem: The gear setting is disturbed or worn-out clutch plate. Change the gear
setting and replace the clutch plate.
3. Improper balance: The tyres do not have proper air. Inflate the tyres for proper balance.
4. Motorcycle vibrates: The engine foundation, mudguards, and side panel’s nut-bolts are loose.
Apply proper torque to the nut-bolts.
5. Motorcycle jerks in operation: The power transmission of the motorcycle is not proper. Adjust
the tension of the transmission chain, replace the chain or chain sprockets.
6. Less average: Loss of average (distance/fuel) due to fuel wastage in carburetor of the
motorcycle. Fine tune the carburetor to achieve optimum average of mileage per liter of petrol.
7. Wearied tyres: poor power transmission efficiency, misalignment of the motorcycle tyres
bearing, wearied block unit and wearied gears in the gear box. Replace tyres, change the
affected parts of the power transmission, replace the tyres bearings, replace the piston bock unit,
replace the wearied gears and bearings of the gear box.,
8. Side indicators and other lights not working: Loose electricity connections or fused bulbs.
Replace fused bulbs and fix loose connections.
 9. Horn not working – Loose electricity connection or faulty horn. Fix the loose electricity
connection or replace the faulty horn with new one.
10. Loose side indicators: The side indicators are loose. Torque the screws and bolts of the indicator.
11. Brake not working: The brake shoes of the motorcycle are wearied. Replace with new brake
shoes.
12. Shock absorbers not operating properly: Shock absorber spring is damaged, and oil is leaking.
Replace old shock absorbers with new shock absorber set.

The above problems are indication of maintenance requirement. Fix the problems as soon as possible for
optimum operation of motorcycle at minimum cost.

Critical problem symptoms

Critical problems can cause severe damage. Proper observation and analysis and planning of the
problems are is required to fix these problems. Most of the experienced mechanics can observe these
problems and provide solution. None of the customer is recommended to carry out these fixing
procedures. Brakes doesn't operate at high speeds is typical example of critical problem. The problem is
caused mostly due to wearied brake shoes. Brake shoe replacement is a typical fix to this problem. A
thorough examination of the brake drum and brake actuating mechanism is required for proper fix.

Characteristic of critical problems:

1. Impact is not observed at lower speeds
2. Problem cannot be noticed at normal conditions
3. Fix should be applied after thorough examination
4. Scheduled checks for maintenance
Examples:
1.Power transmission assembly not working properly- Chain, transmission gears and wheel bearings are
not working properly.
2.Gear box noise: Gears of the gear box are wearied out and require replacement
3.Noisy piston block unit at higher speeds: Piston bearings wearied out and require replacement

Immediate attention to these symptoms prevents major financial losses. The maintenance should be
planned after careful observations and analysis. This maintenance should be done by experienced
mechanics or engineers.
Estimation:
Estimation is critical process of the motorcycle maintenance. The process depends on the experience of
the mechanic, observations, and analysis of the affected parts. The maintenance fix for long or short term
decides the budget in the estimation. Cost is a major factor for the maintenance.
The estimates are made for the clarification of the motorcycle owners. The estimate also serves as the
history document at the garages. The estimate is created and shown to the motorcycle owner for budget
approval. The running parts like nut, bolts, packing sets, lubricants, and sealants are not considered in the
estimates as these parts are standard for the maintenance. Once the budget is approved, the spare parts are
purchased and provided to the shop floor mechanic for the maintenance execution.
The estimates are created just for the clarification of the maintenance, the mechanic already know the
cost and performance aspect of the maintenance by the experience.

Example: Estimation process of piston block maintenance

Observations: Block noise at the standing position of a running engine and under various loads.

a. Humming noise: Wearied piston rings

b. Peak periodic noise: As the load increases, peak periodic noise increases. Connecting rod and bearings
are wearied.
c. Block vibrates at increased loads: Block nut bolts are loose
d. Bad performance at high speeds: Block packing has leakage
e. Engine stops at higher speeds: Wearied crank shaft bearings

Based on the observations the piston or piston rings or block or cranks shaft bearings or connection rod
unit is replaced. The analysis is purely based on the experience. Now, the estimate is created with the list
of the spares, time, and the labor cost of the maintenance.
Maintenance Execution:
Maintenance execution involves execution of several processes and procedures in sequence.
The maintenance procedures may vary according to various motorcycle models but the processes remain
the same. Certain automobile manufacturers make changes in the motorcycles for performance
improvement. These changes are applicable to few motorcycles
Motorcycle maintenance risk factors:

1.Degraded quality tools damage the motorcycle parts

2.Improper observations and analysis often ignores the problems
3.Improper spare can damage the motorcycle assembly.

Observations, analysis, and planning are major sections of the motorcycle maintenance. Maintenance
logs are common in executions. These help to identify problems in the procedures. Some motorcycle
mechanics follow these processes and maintain logs system in workshops. Some mechanics have
mastered the skill of motorcycle maintenance on specific motorcycle models. Every motorcycle
manufacturer organizes training camps for the mechanics. Motorcycle owners can attend these camps to
understand the basics of their motorcycle model.

Prerequisites and tool requirements:

Motorcycle maintenance requires ample time for the observations, analysis, and planning. The spares
availability is a major factor for motorcycle maintenance. All the necessary spares should be purchased
before opening the motorcycle assembly. The maintenance process should not be carried out on
weekends as the spares shop are close. As far as possible purchase original spares for the critical parts
like bearings, block-piston, gears, and spark plug etc.
Approach big garages for critical maintenance as the quality of services is good. Small garages mostly
cheat the customers.

A motorcycle garage requires all the normal tools like ring, fix, box spanners, screwdriver set, and box
spanners. All the mentioned quality tools are available at local tool shops.

Typical fixing processes:

All the fixes for motorcycle maintenance are standard. These fixes are predefined procedures for different
motorcycle models. The identification of the problem depends on the observations, analysis, and
experience of the motorcycle mechanic.
Types of fixes:
Following are the motorcycle maintenance fixes:

Minor fixes:
The fixes are not required for the basic operation of the motorcycle like faulty horn, loose mud guard and
faulty side indicators etc. The motorcycle can work without maintenance.

Minor fixes list:

 Headlight not working- Fused bulb or faulty switch
 Front wheel brake not working – Wearied brake liners or faulty control cable
 Speedometer not working – Speedometer problem or faulty cable
 Loose mud guard – Loose nut-bolts or broken mudguard
 Torn seat cover - Seat cover replacement
 Loose chain cover – Loose support nut-bolts
Major Fixes:
The major fixes are required for the basic operation of the motorcycle. For example, spark plug not
working, block piston cease, ignition system problem, punctured tyre. You cannot operate the motorcycle
by neglecting a major fix.
Major fixes list:
 Broken transmission chain
 Jammed rear wheal
 Broken gear
 Broken front wheel bearing
 Broken clutch cable
 Jammed handle bearing

Post Fix checks:

Post fix checks are important for successful maintenance process execution. These checks involve checks
of the replaced parts. Mechanics have checklists for various fixes.

Motorcycle front wheel bearing replacement checklist:

1. Check the old bearing for physical wear near the outer ring. Wear indicates damage to the
bearing housing. Replace the housing.
2. Check the new bearing for grease to ensure proper lubrication.
3. During assembly check the speedometer and brake cables for any wear.
4. During assembly check the torque of front wheel main nut and bolt.

Gear box setting checklist:

1. Try operating the gears at various speeds and load condition of the motorcycle
2. Observe the gear shifting for any type of noise.

Post fixes are implemented for all types of repairs. Typically, these checks consist of checking the
motorcycle assembly nut-bolts for torque, proper operation of various parts at variable loads and speeds.
Maintenance Analysis:
Maintenance analysis is very important process for the smooth operation of the motorcycle.
It is typically executed after few days of the maintenance. Following are typical observations for the
maintenance analysis:
 Part’s Noise
 Vibration
 Deformities
 Wear and tear of parts

E.g., Maintenance analysis observations for the block- piston replacement are following:
1. Abnormal noise
2. Average (distance traveled /fuel unit)
3. Pickup power of the motorcycle

Maintenance analysis is typically based on the experience of the motorcycle mechanic as motorcycle
maintenance is mostly cheap. Few maintenance processes are costly. In absence of the maintenance
analysis for the above example crank shaft bearings and the block piston unit can create severe damage.
Maintenance analysis is very important for the cost-effective operation of the motorcycle. The analysis
should be carried out at various loads and speeds.

Maintenance Performance:
Maintenance performance evaluations are the checks carried out at regular intervals. It is important to
measure the cost effectiveness of the maintenance. The reliability of the repair is measured by the checks
of parts. For example, brake, piston, clutch, Spark plug, and wheels etc. The engine is made to run at
specified speed for predefined time intervals. The motorcycle mechanics mention the positive part of the
performance observations.
The data obtained is useful for future repairs similar model of motorcycles. Although every motorcycle is
a unique case as its physical conditions and uses are different, but the data is useful to certain extent.

e.g. Motorcycle performance table for front wheel assembly:

Sr.No. Performance observations Result

1 Check for noise Nil
2 Smooth operation of the wheel at different speeds noisy at high speed
3 Noise observation during brake operation Nil
4 Speedometer gears normal function

Maintenance results:
Motorcycle maintenance is mostly done for the critical parts and normal parts are neglected; this practice
is not good as the parts near to the damaged section are also affected. After some time, other parts also
stop working. While you do maintenance of your motorcycle, carefully analyze the motorcycle parts as
precaution.
The observations of various parts like seat cover, side panels, tyres, shock absorbers are required but it is
not critical. These parts are required to carry out auxiliary operation of the motorcycle. These
observations are taken at regular intervals (monthly). The results are very important due to direct relation
with the cost. Higher cost gives fast and reliable repairs.
Conclusion
The motor motorcycle maintenance is complex art; it requires years of experience to study and
implement fixes. It is a mechanical job; not intellectual. You are required to carry out at least 2-3 similar
fixes, to accomplish a good fix. Motorcycle mechanics possesses years of experience on same or almost
identical motorcycles to become experts for a class of motorcycle.
I always recommend an experienced motorcycle mechanic to carryout maintenance operations as
incorrect fixes can cost life.