Motorcycle Basics TechBook by Matthew Coombs incorporating material from the Haynes Motorcycle Basics Manual by Pete Shoemarlt

-,

A book in the HiI)'MS T IIChBook s.ne. Printed In the USA

Haynes Publishing Sparkford, Yeovil, Somerset 6A22 7JJ, England

Haynes North America, Ine

113760

(3515-224)

All right. reMJVe<l. No part of thIa book may !Mo ~ or trwmnitted In any form or by any me,n,. eIe<:trorolc or mechanical, Including photo­copying. recording or by any Information .tor. 01" ratrl.".1 sytltem, without permission In writing fr'om the copyright holder.

861 Lawrence Drive, Newbury Park. California 91320, USA ISBN 1 85960 515X

British Ubrary Cataloguing in Publication Dat. A catalogue record for this book Is available from the BritIsh Ubr8ty

Libntry of Cong,..s Cat8log Card Number 2001131367

Editions Haynes 4, Rue de l'AbretNOir 92415 COURBEVOIE CEDEX, France

Haynes Publlshiflg Nordiska AB Box 1504, 751 45 UPPSAlA, Sweden

I Introduction Page 003

About this book Page 003

Acknowledgements Page 003

Safety firstl Page 004

Chapter 1 Engine Page 101

Chapter 2 Fuel system and exhaust Page 201

Chapter 3 Ignition Page 301

Chapter 4 Transmission Page 401

Chapter 5 Engine lubrication and cooling Page 501

Chapter 6 Wheel, brakes and tyres Page 601

Chapter 7 Front suspension and steering Page 701

Chapter 8 Rear suspension Page 801

Chapter 9 Frames and handling Page gol

Chapter 10 Electrics Page 1001

Technical Terms Explained Page REFol

Index Page REF011

Index

A

Accelerator pump (carburettor) - 2.8 Air and air-assisted suspension - 7.6, 8.7 Air cooling - 5.12 Air cut-off valve (carburetror) - 2.8 Air fitter - 2.22 Air induction systems - 2.26 Air sensors - 2.1 B Airbox - 2.23 All-indirect gearbox - 4.11 Alternator - 10.5, 10.8 Anti-dive - 7.9 Anti-lock brakes - 6.15 Aspect ratio (tyre) - 6.7 Aspin valve - 1.24 ATAC -l.13 ATU - 3.9 Automatic transmission - 4.3, 4.1 4

B

Balance (engine) - 1.27 Balancing (carburettor) - 2.16 Battery - 10.10 Battery and coil ignition system - 3.8 Beam frame - 9.4 Belt drive

linal drive - 4.19, 8.5 transmission - 4.14

Bodywork -9.7 Bore (engine) - 1.34 Brake fluid - 6.11 Brake light switch -10.24

Brakes - 6.8 et seq Bulbs- l0.1 4,10.16 Bypass valve (oil) - 5.9

c Caliper (brake) - 6.13 Cam chains and tensioners - 1.22 Camshafts -l .1 S Cantilever suspension - 8.12 Carbon fibre wheels - 6.4 Carburettors - 2.2 10 2.16 Cartridge damper (forks) - 7.6 Cassette gearbox - 4.11 Cast alloy wheels - 6.3 Catalytic converter - 2.27 CDlsystem -3.10 Centre of gravity - 9.2 Chain drive - 4.17, 8.5 Choke (carburettor) - 2.4 Closed-loop control - 3.17 Clutch - 4.3, 4.15 Clutch switch - 10.24 Coil (ignition) - 3.2 Composite wheels - 6.4 Coolant - 5.13

Index REF- l l

Coolant temperature senders and sensors - 10.26 Cooling system - 5.1 et seq Cradle frame - 9.4 Crankcase breather/emission control - 2.25 Crankshaft - 1.3 Cross rotary valve - 1.24 CV (constant velocity) carburettor - 2.11, 2.13 CVT (constantly variable transmission) - 4.14 Cylinder - 1.3

REF'12 Index

D

Damping (suspension) -7.4, 8.8, 8.11 Deflector pistons - 1.6 Desmodromic valves - 1 .23 Detonation - 3.6 Digital ignition - 3.13 Direct top gearbox - 4.10 Disc brakes - 6.10 Disc valve - 1.9 DOHC (double overhead camshaft) engine - 1.18 Drum brakes - 6.9

E

Electrical system - 10.1 et seq Electronic ignition - 3.9 Emission control systems - 2.24 Emulsion tube (carburettor) - 2.7 Engine - 1.1 etseq Engine management - 3.15 Evaporative emission control - 2.26 Exhaust emission control - 2.26 Exhaust system - 2.2, 2.27 EXUP -2.2B

F

Fairing - 9.7 Fitter

air - 2.22 oil- 5.4, 5.7

Final drive - 4.17 Fixed venturi carburettor - 2.9 Float (carburettor) - 2.3, 2.14 Fluid level switches - 10.25 Flywheel generator - 3.7, 10.3, 10.4 Frame - 9. 1, 9.2, 9.4 Front forKs - 7.2 Four-strokeengine-l .3,l.14,1 .16,1.22,l.24,5.3 Fuel - 2.1 Fuel injection

four-stroke engine - 2.16 two-stroke engine - 1.13

Fuellnjectors -2.18 Fuel level senders and sensors -10.25 Fuel pump - 2.17, 2.22 Fuel system - 2.1 et seq Fuel tank and tap - 2.21 Fuses -10.27

G Gearbox

automatic - 4.3, 4.1 4 manual - 4.3, 4.9

Gearchange mechanism - 4.11 Gearing - 4.2, 4.9 Generator (f1ywheeij - 3.7, 10.3, 10.4 Girder forKs - 7.11

H Handlebar switches -10.26 Handling - 9.6 Horizontal engines - 1.30, 1.31, 1.32, 1.34 Horns - 10.21 Hub (wheel) - 6.2 Hub centre steering - 7.13, 7.14 Hydraulic brakes - 6.10, 6.11, 6.13 Hydraulic torque converter - 4.16 Hydraulic valves - 1.20

I Idlespeed -2.14 Ignition coil - 3.2 Ignition switch - 10.26 Ignition system - 3.1 et seq Ignition timing - 3.5 In-line engines - 1.29, 1.30, 1.31 , 1.32, 1.34 Injectors (fuel) - 2. 18 Instrumentation - 10.21 Intake system - 2.2, 2.24

J

Jets (carburettor) - 2.15

K

Kickstart mechanism - 4.1 9 KIPS- 1.12 Knock - 3.6

L

Lead-acid battery - 10.10 Leading link suspension - 7.10 Ughting systems - 10.14 Unked brakes - 6.17 Liquid cooling - 5.13 Load rating (tyre) - 6.8 Loop scavenging - 1.6 Lubrication - 5.1 et seq

four-stroke engines - 5.3 two-stroke engines - 5.10, 5.12

M

Maintenance·free battery - 10.11 Magnesium alloy wheels - 6.4 Main circuit (carburettor) - 2.7 Mapping - 3.13, 3.' 7 Master cylinder (brake) - 6.13 Monoeoque chassis - 9.6 Mono.hock -S.12

N

Needle circuit (carburettor) - 2.6 Neutral switch -10.23

o Offset (steering) - 7.14 OHV (overhead valve) engine -1.16 011 bypass valve - 5.9 011- 5.2 011 cooler - 5.9 011 flHer - 5.4, 5.7 011 pressure - 5.8 0Ilpump- 5.7,5.11,5.12 • One-way clutch - 4.7 Open-loop control - 3.17 Oxygen sensor- 2.19,2.27

p

Parallel twin engines - 1.29, 1.30 Pilot cIrcuit (carburettor) - 2.6 Pilot mixture (carburettor) - 2.14 Piston - 1.3, 1.6 Poppet valve - 1.15, 1.22 Portlng (two-stroke engine) - 1.5, 1.10 Pre-ignition - 3.6 Pre-mix lubrication - 5. 10 Pressure cap (radiatOf1 - 5.14 Pressure relief valve (oil) - 5.8 Primary drive - 4.3 Pump

fueI- 2.17, 2.22 oil - 5.7, 5.", 5.12 water - 5.15

R

Radiator -5.14 Rake -7.14 Rear suspension arrangements - 8. 11 Rear suspension units - 8.6 Regulator (voltage) - 10.5,10.9

Relays -10.27 Rim (wheel) - 6.2 Rising rate rear suspension - 8.12 Rotary engine - 1.35 Rotary valve (cross) - 1.24

s Sealed beam headlights - IO.16 Selector mechanism (gear) - 4.11 Self-cancelling turn signals - 10.20 Sensors - 2.18, 2.19, 3.14, 3.18 Shaft drive - 4.18, 8.5 Shock abSOfber (rear) - 8.6 Slde·stand switch -10.24 Silencer - 2.27 Single cylinder engines - 1.28

Index REFo1 3

Single-sided swing arm front suspension - 7.13 Slide carburettor - 2.10, 2.13 SIIPPtW clutch - 4.8 SOHC (single overhead camshaft) 8flglne - 1.17 Spark plug - 3,3 Speed rating (tyrel- 6.7 SpIne frame - 9.4 SpIlt rim wt\e4Hs - 6.4 Spoku -6.2 SprIngs (suspension) - 7.4, 8.7 Square four engine - 1.33 Starter circuit (carburettor) - 2.3 Starter clutch - 4.7 Starter-dynamo - 10.14 Starter motor - 10.12 Starter relay - 10.14 Steering - 7.13, 9.6 Stroke (engine) - 1.34 Supercharging - 2.19 Suspension (front) - 7.1 et seq

girder fOl1ui - 7.11 leading and trailing link - 7.10 single-sided swingarm - 7.13 telescopic for\( - 7.2 wishbone - 7.12

Suspension (rear) - 6.1 et seq linkages - 6.11 swingarm - 6.2

SV (side-valve) engine -1.16 Swingann

front-7.13 rear - 8.2

Synchronising (carburettOf1 - 2.16

T

Tank and tap (fuel) - 2.21 Telescopic forks - 7.2 Temperature gauge senders and sensors - 10.26 Temperature sensor - 2.19 Tensioner (cam chain) - 1.22 Thennostat - 5.15 Throttle (carburettor) - 2.3 Throttle body - 2.18 Throttle position senSOf" - 2.8, 2. 19

REF.14 Index TIckler (carburettor) - 2.4 Timing .

ignition - 3.5 valve-1.7,1.24

Torque - 4.2 Torque converter (transmission) _ 4.16 Trail -7.t4 Trailing link suspension - 7.10 Transfer ports - 1.8 Transistorised ignition - 3.13 Transmission - 4.1 er seq Trellis frame - 9.4 Triple cylinder engines - 1.30 Tuning - 2.15, 2.'9 Turbocharglng - 2.19 Turn signal systems - 10.17 Twin cylinder engines - t.29 Two-stroke engine - 1.3, 1.5, 1.6, 1. ' 0, , .13, 5. 10 Tyres - 6.3, 6.5, 6.7

u Unsprung weight - 7.1

v Valve

Aspin -1.24 Cross- 1.24 Oesmodromic - , .23 disc-l.9 reed-l.7 poppet-l.1S, 1.22

Valve bounce and float - 1.17

Valve timing - 1.7, , .24 Variable ratio belt drive transmission - 4.14 Variable valve timing - , .26 Vee-eogines - 1.34

vee-five - 1.34 vea-lour - 1.33 vea-Wee - l.3t vee-twin - 1.30

Vibration - 1.26 Voltage regulator - 10.5,10.9

w Wankel engine - , .35 Warming system (carburettor) - 2.8 Warning lamp systeml - 10.23 Water cooling - 5. ' 3 Waterpump -S.15 Wheelbase -7.15 Wheels -S.2 Wiring -10.26 Wishbone suspension -7.12

y

YPVS -1.11

z Zener diode - 10.5

l