Motorcycle Repair

Lesson 1: Shop Safety and Tools. Shop safety; bench vises; torque wrenches; drivers; drills; die grinders; files; hacksaws; socket tools; punches; chisels; pliers; hammers; threaded fasteners; non-threaded fasteners; stress forces; threaded fastener standards; thread repair.

Lesson 2: Internal Combustion Engine Theory. The internal combustion process; the three phases of combustion engine operation; abnormal combustion; efficient combustion; compression ratios.

Lesson 3: Four-Stroke Engines: Part 1. Upper-end components of the four-stroke engine; order of operation; configurations; operation of the engine cylinder head, engine camshaft and parts.

Lesson 4: Four-Stroke Engines: Part 2. Lower-end engine and exhaust system components; function and servicing of the piston and related parts; four-stroke engine cylinder types; important service procedures; crankcase designs; anti-friction components; gaskets and other seals.

Lesson 5: Two-Stroke Engines. Two-stroke engine components; configurations; two-stroke port system and components; operation of the engine cylinder and related components; expansion system and components.

Lesson 6: The Drive Train and Starting Systems. Different gear types; torque; rpm; primary drive systems; an explanation of various clutches and transmissions; starting systems and components.

Lesson 7: Lubrication and Cooling Systems. Composition and properties of oil; testing and classification of lubricating oils; keeping lubricants at peak efficiency; lubrication systems for two-stroke and four-stroke engines; air and liquid cooling systems.

Lesson 8: Fuel Systems and Carburetion. Key components: the fuel tank, fuel lines and petcock; fuel additives and effectiveness; emissions and their sources; carburetion; carburetor, fuel injection and turbocharger designs.

Lesson 9: Basic Electrical Theory. The four major electrical systems and subsystems of motorcycles: starting, ignition, lighting and charging; direct and alternating currents; principles of electricity and magnetism; types of motorcycle ignition systems.

Lesson 10: Ignition Systems. Relationship between the fuel and ignition systems; how to test ignition system components; two types of motorcycle ignition systems; methods of troubleshooting; function of the battery and the magneto as they relate to the ignition system.

Lesson 11: Charging Systems and Starting Motors. Principles of operation of the charging system; charging system types and their tests; function of the component parts of the starter motor; how DC charging systems work.

Lesson 12: Lighting and Accessories. The headlight, taillight, stoplight, turn signals and instrument illumination systems; direct and indirect lighting; warning systems; brake-fluid indicator; override system.

Lesson 13: Wheels and Tires. The four types of wheels; wheel components; important wheel maintenance procedures; types of wheel bearings; step-by-step tire maintenance and repair.

Lesson 14: Frame and Suspension. Frame construction, design, components and maintenance; suspension; rear suspension components; front suspension and steering; steering geometry; correcting handling problems.

Lesson 15: Brake Systems. An introduction to brake systems; drum, hydraulic disk, cable-disk and anti-lock brakes; floating brake mounts; servicing anti-dive systems; unified brake systems; servicing brake systems.

Lesson 16: Four-Stroke Engine Tune-Up and Service. The basic tune-up; compression check; battery, spark plug, cable, tire, wheel, rear chain, sprocket and safety inspections; oil and filter change; ignition system, air filter and drive shaft service; cam chain, valve, clutch and brake adjustments; carburetor synchronization; test ride.

Lesson 17: Two-Stroke Engine Tune-up and Service. The basic tune-up; compression check; main bearing, battery, spark plug, cable, tire and safety inspections; transmission, oil injection, air filter, ignition and exhaust systems; drive shaft, drive chain, and sprocket service; clutch and brake adjustments; test ride.

Lesson 18: Career In The Motorcycle Industry. Trends in the motorcycle industry: how technological advances have affected the motorcycle market; career options: entry-level apprentice and line technician, service writer, parts manager, and service manager.