Motorcycle Engineering

Motorcycle Engineering is a primer and technical introduction for anyone interested in motorcycles, motorcycling, and the motorcycle industry. It provides insight into how motorcycles are made and operated. Motorcycles, mopeds, and scooters are important factors in world transport, and they are playing an increasingly important role in transport policy as we move towards greater environmental awareness. Motorcycles and scooters give freedom of personal transport that enable large commuter distances to be covered quickly and easily. Their small footprint offers easy storage as only minimal space is required. To celebrate the importance of motorcycles on the world stage, a brief history is included with a detailed timeline detailing the development of the motorcycle alongside major world events. Written in an accessible fashion, no previous knowledge of engineering or technology is required, as all technical terms are readily explained and a glossary and abbreviation list is included. Whether you are an enthusiast, racer, student, or industry professional, you will surely find this an enjoyable read and a handy reference book on your shelf. The complex engineering behind the machines is explained in easy-to-understand terms and supported by 350 images. It covers a range of motorcycle types, and will be particularly useful for students on motorcycle and motorsport courses such as those run by the IMI and City & Guilds, as well as BTEC programmes. Cover 1 Half Title 2 Title Page 4 Copyright Page 5 Contents 6 Abbreviations and symbols 12 General abbreviations 14 Preface 18 1. Power unit – engine 20 Identification 21 Engine performance 21 Engine construction 27 Combustion 44 Cylinder head 46 Short block assembly 48 Induction 50 Exhaust 51 2. Ignition and fuel 54 Ignition system 54 Battery 55 Ignition switch 55 Ignition coil 56 Fuel system 64 Air:petrol ratio 69 Petrol injection 70 Electronic control unit 71 3. Lubrication and cooling 74 Lubrication system 74 The cooling system 84 4. Health, safety, security, and the environment 94 Personal health and safety procedures 94 COSHH 105 RIDDOR 105 Miscellaneous topics 112 5. Motorcycle types 114 Motorcycle categories, ages, and licence requirements in the UK 114 Safety equipment 115 6. Materials for motorcycles 130 Metallic materials 130 Manufacture of steel 131 Annealing and tempering 132 Classifications of steel 132 Alloying metals used with steel in motorcycle frames 134 Work hardening and fatigue failure 136 Properties of materials 136 Frame tubing 137 Reynolds tubing 137 Columbus tubing 139 7. Frames and fairings 142 Frames 142 Fairings 144 8. Electric motorcycles 152 Rules and regulations 152 Electric bicycle construction 155 Health and safety 161 9. Soldering, brazing, and welding 162 Comparison of fusion and nonfusion jointing processes 162 Aluminium brazing 168 Health and safety and the environment 171 Safety measures 173 General equipment safety 175 Gas-shielded arc welding (MIG, MAG, and TIG) 175 10. Running gear and braking 178 Running gear 178 Suspension and steering 178 Wheels and tires 185 Wheels 187 Tires 188 Braking system 195 Mechanical brakes 197 Hydraulic brakes 200 Drum brakes 203 11. Motorcycle electrical and electronic systems 216 Battery 216 Alternator 220 Starter motor 221 Vehicle circuits 222 Lights 228 12. The motorcycle industry 232 Traditional motorcycle shop 232 Assembly methods: modern retailing 237 Other motorcycle industry services 239 Trade associations 241 13. Reinforced composite materials 244 Introduction 244 Basic principles of reinforced composite materials 245 Manufacture of reinforced composite materials 246 Types of reinforcing material 247 Resins used in reinforced composite materials 249 Catalysts and accelerators 250 Pre-impregnated material (Pre-preg) 255 14. Data 258 The norm 258 Understanding and using data 259 Bar charts and stacking bar charts 261 Pie charts 261 Normal distribution 262 Profit and loss account (PLA) 264 15. Science terminology 268 SI system and common units 268 Decimals and zeros 269 Accurate measuring 270 Capacity and volume 272 Temperature and heat 272 Force and pressure 273 Amps, volts, ohms, watts, and kirchhoff 274 Friction 275 Some common laws of mechanical engineering 276 Impact and momentum 276 16. Transmission 278 Clutch 278 Gearbox 283 17. Tuning and customizing 294 Modifications 294 Vehicle-fixed coordinate system 312 Earth-fixed coordinate system 312 18. Inspection, test, and rebuild 318 Safety first 318 Test and rebuild 321 Costs 323 Health and safety and the environment 325 19. Sustainability 344 The three centric concerns of sustainability 344 Transforming our world: the 2030 agenda for sustainable development 346 Discussion 347 Insurance 348 20. Brief history of motorcycles 350 Purpose and use 353 World war I 354 Between the wars 358 World war II 359 The golden era 359 1969 – The sea change 361 The millennium 363 Timeline 364 Appendix – Apprenticeship standard fora motorcycle technician 370 Glossary 374 Index 378 Motorcycle;,Power,unit;,Combustion;,Induction;,Ignition;,Fuel,system;,Lubrication;,cooling,system;,COSHH;,RIDDOR;,Frame,tubing;,Reynolds,tubing;,Columbus,tubing;,Frames;,Electric,motorcycles;,Suspension;,steering;,Braking,system;,Alternator;,Transmission;,Sustainability. Motorcycle,Power unit,Combustion,Induction,Ignition,Fuel system,Lubrication,cooling system,COSHH,RIDDOR,Frame tubing,Reynolds tubing,Columbus tubing,Frames,Electric motorcycles,Suspension,steering,Braking system,Alternator,Transmission,Sustainability.