Quartz halogen headlight bulb construction

Rack-and-pinion Apinion gear on the end of a

shaft that mates with a rack (think of a geared

wheel opened up and laid flat). Sometimes used

in clutch operating systems.

Radial playUp and down movement about a

shaft.

Radial ply tyresTyre plies run across the tyre

(from bead to bead) and around the

circumference of the tyre. Less resistant to tread

distortion than other tyre types.

RadiatorA liquid-to-air heat transfer device

designed to reduce the temperature of the

coolant In a liquid cooled engine.

RakeA feature of steering geometry - the angle

of the steering head in relation to the vertical (see

Illustration).

ref.52 Technical Terms Explained

Rebore Providing a new working surface to the

cylinder bore by boring out the old surface.

Necessitates the use of oversize piston and

rings.

Rebound damping A means of controlling the

oscillation of a suspension unit spring after it has

been compressed. Resists the spring's natural

tendency to bounce back after being compressed.

Rectifier Device for converting the ac output of

an alternator into dc for battery charging.

Reed valve An induction system commonly

used on two-stroke engines.

Regulator Device for maintaining the charging

voltage from the generator or alternator within a

specified range.

Relay A electrical device used to switch heavy

current on and off by using a low current auxiliary

circuit.

Resistance Measured in ohms. An electrical

component's ability to pass electrical current.

RON (Research Octane Number) A measure of

a fuel's resistance to knock.

rpm revolutions per minute.

Runout The amount of wobble (in-and-out

movement) of a wheel or shaft as it's rotated.

The amount a shaft rotates out-of-true'. The out-

of-round condition of a rotating part.

s

SAE (Society of Automotive Engineers) A

standard for the viscosity of a fluid.

Sealant A liquid or paste used to prevent

leakage at a joint. Sometimes used in

conjunction with a gasket.

Service limit Term for the point where a

component is no longer useable and must be

renewed.

Shaft drive A method of transmitting drive from

the transmission to the rear wheel.

Shell bearings Plain bearings consisting of two

shell halves. Most often used as big-end and

main bearings in a four-stroke engine. Often

called bearing inserts.

Shim Thin spacer, commonly used to adjust the

clearance or relative positions between two

parts. For example, shims inserted into or under

tappets or followers to control valve clearances.

Clearance is adjusted by changing the thickness

of the shim.

Short-circuit An electrical condition where

current shorts to earth (ground) bypassing the

circuit components.

Skimming Process to correct warpage or repair

a damaged surface, eg on brake discs or drums.

Slide-hammer A special puller that screws into

or hooks onto a component such as a shaft or

bearing; a heavy sliding handle on the shaft

bottoms against the end of the shaft to knock the

component free.

Small-end bearing The bearing in the upper

end of the connecting rod at its joint with the

gudgeon pin.

Spalling Damage to camshaft lobes or bearing

journals shown as pitting of the working surface.

Specific gravity (SG) The state of charge of the

electrolyte in a lead-acid battery. A measure of

the electrolyte's density compared with water.

Straight-cut gears Common type gear used on

gearbox shafts and for oil pump and water pump

drives.

Stanchion The inner sliding part of the front

forks, held by the yokes. Often called a fork tube.

Stoichiometric ratio The optimum chemical

air/fuel ratio for a petrol engine, said to be 14.7

parts of air to 1 part of fuel.

Sulphuric acid The liquid (electrolyte) used in a

lead-acid battery. Poisonous and extremely

corrosive.

Surface grinding (lapping) Process to correct a

warped gasket face, commonly used on cylinder

heads.

T

Tapered-roller bearing Tapered inner race of caged needle rollers and separate tapered outer race. Examples of taper roller bearings can be found on steering heads.

Tappet A cylindrical component which transmits motion from the cam to the valve stem, either directly or via a pushrod and rocker arm. Also called a cam follower.

TCSTraction Control System. An electronically-controlled system which senses wheel spin and reduces engine speed accordingly. TDCTop Dead Centre denotes that the piston is at its highest point in the cylinder. Thread-locking compound Solution applied to fastener threads to prevent slackening. Select type to suit application.

Thrust washer A washer positioned between two moving components on a shaft. For example, between gear pinions on gearshaft. Timing chainSee Cam Chain. Timing light Stroboscopic lamp for carrying out ignition timing checks with the engine running. Top-end A description of an engine's cylinder block, head and valve gear components. Torque Turning or twisting force about a shaft. Torque setting A prescribed tightness specified by the motorcycle manufacturer to ensure that the bolt or nut is secured correctly. Undertightening can result in the bolt or nut coming loose or a surface not being sealed. Overtightening can result in stripped threads, distortion or damage to the component being retained. Torx key A six-point wrench. Tracer A stripe of a second colour applied to a wire insulator to distinguish that wire from another one with the same colour insulator. For example, BrAty is often used to denote a brown insulator with a white tracer. Trail A feature of steering geometry. Distance from the steering head axis to the tyre's central contact point.

Triple clamps The cast components which extend from the steering head and support the fork stanchions or tubes. Often called fork yokes. Turbocharger A centrifugal device, driven by exhaust gases, that pressurises the intake air. Normally used to increase the power output from a given engine displacement. TWIAbbreviation for Tyre Wear Indicator. Indicates the location of the tread depth indicator bars on tyres.

u

Universal joint or U-joint (UJ) A double-pivoted connection for transmitting power from a driving to a driven shaft through an angle. Typically found in shaft drive assemblies. Unsprung weight Anything not supported by the bike's suspension (ie the wheel, tyres, brakes, final drive and bottom (moving) part of the suspension).

V

Vacuum gauges Clock-type gauges for

measuring intake tract vacuum. Used for

carburettor synchronisation on multi-cylinder

engines.

Valve A device through which the flow of liquid,

gas or vacuum may be stopped, started or

regulated by a moveable part that opens, shuts

or partially obstructs one or more ports or

passageways. The intake and exhaust valves in

the cylinder head are of the poppet type.

Valve clearance The clearance between the

valve tip (the end of the valve stem) and the

rocker arm or tappet/follower. The valve

clearance is measured when the valve is closed.

The correct clearance is important - if too small

the valve won't close fully and will burn out,

whereas if too large noisy operation will result.

Valve lift The amount a valve is lifted off its seat

by the camshaft lobe.

Valve timing The exact setting for the opening

and closing of the valves in relation to piston

position.

Vernier caliper A precision measuring

instrument that measures inside and outside

dimensions. Not quite as accurate as a

micrometer, but more convenient.

VINVehicle Identification Number. Term for the

bike's engine and frame numbers.

Viscosity The thickness of a liquid or its

resistance to flow.

Volt A unit for expressing electrical "pressure" in

a circuit. Volts = current x ohms.

w

Water pump A mechanically-driven device for

moving coolant around the engine.

Watt A unit for expressing electrical power.

Watts = volts x current.

Wear limit see Service limit

Wet liner A liquid-cooled engine design where

the pistons run in liners which are directly

surrounded by coolant (see illustration).

Wet liner arrangement

Wheelbase Distance from the centre of the front

wheel to the centre of the rear wheel.

Wiring harness or loom Describes the electrical

wires running the length of the motorcycle and

enclosed in tape or plastic sheathing. Wiring

coming off the main harness is usually referred to

as a sub harness.

Woodruff key A key of semi-circular or square

section used to locate a gear to a shaft. Often

used to locate the alternator rotor on the

crankshaft.

Wrist pin Another name for gudgeon or piston

pin.

Note:References throughout this index are in

A

Aim (headlight) -1*14 Air filter

element - 1»18

housing-4» 13 Air/fuel mixture adjustment - 4*4 Alignment (wheel) - 7*16 Alternator-9«21

B

Balancer gear - 2*28

Balancer shaft and bearings - 2»44

Battery

charging - 9*3

check-1*12, REF«45

removal, installation and maintenance - 9»2

specifications - 9»1 Beam (headlight) -1*14 Bearings

engine - 2«36, 2»42, 2*44

general - REF«14

steering head - 1*16,1*23

sprocket coupling - 7*20

swingarm -1*16, 1*23

wheel -1*17, 7*19

- "Chapter number" • "Page number"

Body panels - 8*2 Brake (disc type)

bleeding and fluid change - 7»13

caliper - 7*4, 7*9

disc - 7»6

hose- 1*23, 7»13

master cylinder - 7*7, 7»11

pads-W, 7*3, 7*9

seal renewal - 1 »22 Brake (drum type)

cam lubrication - 1 «23

pedal freeplay and height - 1 »8

removal, inspection and installation - 7»14

shoes -1 «8 Brake fluid

change- 1*18, 7-14

level check-0*14 Brake light

bulb-9*7

switches-1*11, 9*8 Brake pedal - 1*8, 6*2 Brake specifications - 7*1 Brake system check -1*11 Breather (crankcase) - 1 »9 Bulbs

brake/tail light - 9»7

headlight and sidelight - 9«4

instrument and warning lights - 9»12

ratings - 9*2

turn signal - 9»8

REF»54 Index

C

Cables

choke- 1*14

clutch- 1*8,2*22

lubrication - 1 *9

speedometer - 9*9

throttle-1*13 Caliper (disc brake) - 1 *22, 7*4, 7*9 Camchain and guide/tensioner blades - 2*45 Camchain tensioner - 2*10 Camshafts

removal, inspection and installation -2*11

specifications - 2*2 Carburettors

air/fuel mixture adjustment - 4*4

disassembly, cleaning and inspection - 4*5

reassembly and float height check - 4*8

removal and installation - 4*4

separation and joining - 4*10

specifications - 4*1

synchronisation -1 *14 Centre stand

check - 1*15

removal and installation - 6*4 Charging (battery)- 9*3 Charging system

alternator-9*21

regulator/rectifier - 9*22

specifications - 9*1

testing - 9*20 Choke cable

check and adjustment - 1*13

removal and installation - 4*12 Clutch

removal, inspection and installation - 2*23

specifications - 2*2

switch -9*14 Clutch cable

check and adjustment - 1*8

replacement - 2*22 Coolant

hoses - 3*8

level check -0*16

reservoir - 3*2 Cooling system

check -1*11

draining, flushing and refilling - 1 *22

fan and fan switch - 3*3

radiator - 3*6

specifications- 3*1

temperature gauge and sender - 3*4, 9*12

thermostat - 3*4

water pump - 3*7 Connecting rod

bearings - 2*36

removal, inspection and installation - 2*36

specifications - 2*3 Control unit (ignition) -5*4 Conversion factors- REF*26 Crankcase

breather -1 *9

halves - 2*33, 2*54 Crankshaft

removal, inspection and installation - 2*42

specifications - 2*4 Cush drive (rear wheel) -6*17

Cylinder bores

inspection - 2*54

specifications - 2*3 Cylinder compression- 1*23, REF*45 Cylinder head

overhaul -2*17

removal and installation - 2*15

D

Diode-9*15 Disc

front brake - 7*6 rear brake- 7*11 Drive chainchecks -0*16

check, adjustment and lubrication - 1 *6 general advice - REF*18 removal, cleaning and installation - 6*15 slider-1*18, 6*13 specifications - 6*2

E

Electricalsystem

fault finding - 9*2, REF*44, REF*46

specifications - 9*1

wiring diagrams - 9*23 Engine/transmission oil

level check-0*13

oil and filter change - 1 *10 Engine

balancer gear - 2*28

balancer shaft - 2*44

bearings - 2*36

camchain and blades - 2*45

camchain tensioner - 2*10

camshafts - 2*11

compression - 1 *23, REF*45

connecting rods - 2*36

crankcases - 2*33, 2*54

crankshaft - 2*42

cylinder bores - 2*54

cylinder head-2*15, 2*17

idle speed -1*7

initial start-up - 2*55

oil pressure - 1 *23

oil pressure relief valve - 2*31

oil pressure switch - 9*13

oil pump-2*29

oil strainer - 2*29

oil sump - 2*30

piston rings - 2*41

pistons - 2*39

primary drive gear - 2*28

removal and installation - 2*6

running-in - 2*55

specifications- 1*2, 2*1

sprocket-6*16

starter clutch and idle gear - 2*20

valve clearances - 1*19

valve cover - 2*9

valves-2*17 Engine number -0*9 Engine weight -0*10 Exhaust system

check - 1*24

removal and installation - 4*13

Index ref-55

F

Fairing - 8*3

Fan and fan switch (cooling system) -3»3

Fault finding- 5»2. 9«2, REF»35 etseq

Filter

air- 1*18

fuel- 1»12

oil -1*10,2*31 Float height check - 4*8 Footrests - 6*2 Frame - 6»2 Frame number - 09 Front brake

caliper - 7»4

disc - 7*6

master cylinder - 7*7

pads-1*7. 7*3

seal renewal - 1 «22

specifications -7*1 Front forks

check-1*16

oilchange - 1 »24

overhaul - 6*7

removal and installation - 6*6

specifications - 6*1 Front mudguard - 8*4 Front wheel

bearings- 1*17, 7*19

removal and installation - 7»16 Fuel consumption - 0*10 Fuel hoses- 1*12, 1*23 Fuel system checks -1*12 Fuel tank and tap - 4*2 Fuses

check and renewal - 9*3

specifications - 9*1

G

Gaskets (general) - REF»17 Gearboxsee Transmission Gearchange lever - 6»2 Gearchange mechanism -2*32 Ground clearance- 0*10

H

Handlebar switches -9»15 Handlebars - 6*4 Headlight

beam adjustment - 1 »15

bulb renewal - 9*4

removal and installation - 9*6 Height -O10 Horn-9*16

Hoses (general)- REF»19 HT coils

check, removal and installation - 5*3

specifications - 5«1

I

Idle speed - W

Ignition (main) switch -9*13

Ignition system

check - 5»2 HT coils - 5»3 ignition control unit - 5»4 pulse generator coil - 5*3 specifications - 5»1 timing - 5»4 timing rotor - 2«28 Instrumentsbulb renewal -9*12 check and replacement - 9*10 removal and installation - 9»9

L

Legal checks -016 Length -010 Levers - 6*4 Lighting system - 9*4 Lubricants

general - REF»23 ef seq

recommended -1»2 Lubrication

levers, stand pivots and cables -1 »9

specifications - 2*3

M

Main bearings -2*36, 2*42 Main (ignition) switch -9»13 Maintenance

schedule - 1 «3

specifications- 1«2 Master cylinder (disc brake)

front -1»22, 7*7

rear-1«22, 7*11 Micrometer - REF»9 Mirrors - 8*3

Mixture (air/fuel) adjustment - 4»4 Model development - 0*8,0*11 MOT test checks- REF»27 ef seq Mudguard (front) - 8«4

N

Neutral switch-9*13

o

Oil (engine/transmission)

level check -0*13

oil and filter change -1*10

pressure - 1 »23 Oil (front forks) - 1 »24 Oil pressure relief valve -2»31 Oil pressure switch -9*13 Oil pump -2»29 Oil seals (general) -REF»16 Oil sump -2*30 Oil strainer -2*30

ref-56 Index

P

Pads (disc brake) - 1 «7, 7*3, 7*9 Pedal (brake)

adjustment (drum brake) - 1 »8

removal and installation - 6*2 Piston

removal, inspection and installation - 2*39

specifications - 2*3 Piston rings- 2»41 Plastigauge-REF»11 Pressure

cylinder compression - 1 «23, REF»45

engine oil- 1»23

tyre -0*15 Pressure cap (radiator) - 1«11,3»2 Pressure relief valve (oil) -2*31 Primary drive gear -2*28 Pulse generator coil

check, removal and installation - 5*3

specification - 5*1 Pump (oil) -2»29 Pump (water) -3«7

R

Radiator

pressure cap -1*11, 3*2

removal and installation - 3«6

side panels - 8*3 Rear brake (disc type)

caliper - 7*9

master cylinder - 7»11

pads - 1 »7, 7»9

specifications - 7*2 Rear brake (drum type)

cam lubrication - 1 »23

shoe wear check - 1 »8

specifications - 7*2 Rearshocks

adjustment -6» 13

removal, inspection and installation - 6»12

specifications - 6»2 Rear suspension

check-1*16

shocks -6« 12, 6*13

swingarm -1*23, 6*13, 6*15 Rear view mirrors - 8*3 Rear wheel

bearings -1*17, 7*20

removal and installation - 7*18 Regulator/rectifier -9*22 Relay

headlight - 9*4

starter-9« 16

turn signal - 9*8 Rings (piston) -2*41

Rubber damper (sprocket coupling) -6*17 Running-in -2»55

s

Safety precautions- 0*12, 0*16, REF»4 Schedule (maintenance) -1*3

Sealants (general)- REF«17

Seat - 8»2

Seat cowling - 8«2

Seat height-O10

Security- REF«20 et seq

Date: 2016-01-14; view: 937