Standard

Posted: 02/09/07

*State Standard

R Institutionally Developed

*College: DeKalb / North Georgia Technical Colleges

MCT 156 - Motorcycle Troubleshooting and Diagnostics

Course Description

This course will guide the student through a logical sequence of diagnostic checks that will permit fast and accurate identification of problems in all the previously covered systems as well as charging and starting systems. Special tool and diagnostic equipment will be evaluated and used to demonstrate the various options for shop repair. A working knowledge of Internal Combustion Theory will be taught during this course.

Competency Areas	Hours
Troubleshooting brakes, wheel and tires	Class	1
Diagnosing ignition, fuel and cooling systems	D. Lab	2
Evaluating charging and starting systems	P. Lab/O.B.I.	3
Internal Combustion Engine Theory	Credit	3

Prerequisite:	MCT 100, MCT 110, MCT 112
Corequisite:

Course Guide

Competency	After completing this section, the student will be able to:	Hours
		Class	D.Lab	P.Lab/ O.B.I.

Troubleshooting brakes, wheels and tires		2	5	8
Brake adjustment	Properly adjust brakes
Pad and liner replacement	Properly replace pads and or liners as per the repair manual specifications.
Fluid levels and types	Demonstrate knowledge of the difference between DOT 3, DOT 4, and DOT 5 brake fluids and when each should be used.
Wheel alignment and spoke adjustment	Show how to identify warped wheels and adjust tension or replace spokes as necessary.
Wheel bearing adjustment and repair	Disassemble, repack or replace bearings as required.
Wheel Balancing	Demonstrate proper use of shop equipment in placing weights at correct points on rim.
Tire wear patterns	Show how to visually note irregular wear patterns to determine causes of wear.
Tire repair	Demonstrate how to dismount a tire from a rim and patch or replace it as needed.
Diagnosing ignition, fuel and cooling systems		2	5	8
Battery-Point Ignition	Demonstrate how to identify and evaluate individual components and how to repair or replace components as required.
Photo-Optic Ignition	Demonstrate how to identify and evaluate individual components and how to repair or replace components as required.
High Tension Magnetos	Demonstrate how to identify and evaluate individual components and how to repair or replace components as required.
Energy Transfer Magneto	Demonstrate how to identify and evaluate individual components and how to repair or replace components as required.
Capacitor Discharge Ignition	Demonstrate how to identify and evaluate individual components and how to repair or replace components as required.
Diagnosing fuel problems	Show how to inspect for water or other fuel contaminates. Test for intake leak between Carburetor and Engine head.
Inspecting fuel filters and lines	Demonstrate the disassembly and inspect of fuel filters for clogging. Replace as required.
Inspecting carburetors and fuel injection	Show the diagnostic procedures used to determine when carburetor disassembly is necessary.
	Demonstrate the procedures for checking for leaks and contaminants.
	Test for intake leak between Carburetor and Engine head.
	Demonstrate carburetor adjustment using the proper tools and manufacture specifications.
	Demonstrate fuel injection diagnosis and repair.
Inspecting radiators, coolant and hoses	Show how to visually inspect for leaks, collapsed hoses or evidence of blockage.
	Demonstrate how to pressure check a cooling system.
	Perform a thermostat test and replacement.
Evaluating charging and starting systems		3	5	8
Batteries	Describe the two types of batteries used in motorcycles and how they store a charge.
	Demonstrate proper care of batteries.
Principles of Operation	Explain half and full wave rectification.
AC Charging System Designs	Name the components in an AC charging system.
Testing AC Charging Systems	Diagnose, repair and or replace components in the AC system.
DC Charging System Designs	Name the components in an AC charging system.
Testing DC Charging Systems	Diagnose, repair and or replace components in the AC system.
Starter Motors	Explain how the starter, bendix clutch drive and solenoid operate and the purpose of each component.
Testing Starter Motors	Diagnose, repair and or replace components in the starter if needed.
Internal Combustion Engine Theory		3	5	6
2 cycle engine operation	Explain and demonstrate 2 cycle engine operation using a mock-up.
4 cycle engine operation	Explain and demonstrate 4 cycle engine operation using a mock-up.
Lubrication of bearings, valves and chambers	Demonstrate an understanding of the process and necessity of adequate engine lubrication.
Understanding compression	Demonstrate the ability to compute compression ratio and an understanding of its relationship to power, fuel requirements and drivability.

Suggested Resources

Motorcycle Mechanics Institute (1994). Complete Guide to Motorcycle Mechanics. Prentice Hall

Johns, Edmundson and Sharff (1999). Motorcycles, Fundamentals, Service and Repair. Goodheart-Willcox