Motorcycle Service Technology

Intro to Motorcycles,  the class where it all begins.  I was pretty excited upon enrolling into the program and had positive thoughts, that finally I was going to do something that I actually had a interest in.  Unlike most people that go to school for 4-8 odd some years for the sake of an unhappy salary, rather than their own genuine interest of things.  I can speak on behalf of myself, being in school for three years straight building up my general education credits in hopes that I would know what I wanted to do in life at the half way mark.  I do have a few field of interests that I had in mind, but nothing intrigues me more than motorcycles.  Not being born a natural motorhead unlike the majority of certified mechanics out there, but in the process of becoming one.  So for the time being, instead of doing something that I think “should” do, I’m going to go with the what I “want” to do path.

I didn’t know what to expect at first before the first class session, but after  the first day of class I knew I was going to have fun.  A couple loud but funny classmates made up part of it along with hearing the professor’s stories about running off from the cops made everything seem pretty laid-back.  Everything is just more fun at 100mph anyway.  There are times when to be serious,  but you got to have your laughs in too to make the best of things especially when it comes to learning something new. 

My motivation for entering the program wasn’t just for the hell of it, but because there really isn’t room for just being an everyday motorcycle rider without knowing how to fix your own bike.  Every seasoned rider should at least have an idea how their bike works.  Then again, if every motorcycle rider knew how to fix their own bike, there wouldn’t be money to be made when it came to motorcycle repair.  Really though,  that belief is more of my own self expectations and standards. 

Like any other kid growing up, I’ve had a pretty good general interest in motorcycles but I’ve only been riding for about a year now.  And up until now, I’ve had five bikes since then.   Despite that duration maybe that’s a bit bike whore-ish but really it’s because my dumbass self didn’t know how to fix my own bikes.  I would buy something for cheap.  Ride it for a thousand miles and then when something would go wrong on the bike, I wouldn’t know how to fix it.  Then after realizing I was over my head when I took the initiative to do an engine repair, I would just give up and posting the bike on craigslist in hopes I would get half of what I got it for.  I was kind of tired of going through that endless cycle, so that’s when I looked up Chattahoochee Technical College. 

 
I don’t actually have plans in becoming a technician, more so upon my own interest in motorcycles and knowing how to fix my own stuff instead of going to the local bike shop and hearing an $X,XXX amount of dollars on a quote.  Where instead of spending on a 4-figure repair job, it made more sense to invest that 4-figure into an affordable motorcycle repair program.  Ideally though, after I get to the point of knowing what I’m doing, I would like to fix broken down bikes for cheap, fix them and then flip for profit.  And thanks to online websites like craigslist, there is money to be made during the right seasons.  Buy for cheap during the winter time, and then flip for big bucks during the summer.  But whatever happens, happens.  If I finish the program (that in which I hope) and get offered a job on the spot, I might just take it.  

Adjusting Valves on a Kawasaki zx-750 Engine

So in our shop at school, we have a Engine on a mount from a Kawasaki zx-750, a Japanese inline four.  For the past couple  months we have only been working on cruisers and Harleys, and I've been kind of itching to get my hands greasy on a Japanese inline four engine, from the sportsbike perspective.

I own a 1997 Honda cbr600f3 and I have been planning on doing a valve job on it since it's probably due for one for it's age and the current miles on it.  Previous owner said the engine was rebuilt and has 7k miles on it when I got it at 46k.  It does run like it's been rebuilt, but you never can tell.  Valve jobs on your typical sportsbike can usually run from 500-800 at a local motorcycle shop, but hence the reason why I'm in school and all the more motivation to do it yourself repair and adjustment jobs. 

Anyways, since the zx750 engine was out of the frame and already on a mount, it was slightly more easier than if it were still in the motorcycle frame.  Usually when you're working on a inline-four on a sportsbike, there's very little room to work with.  And if you got gorilla sized hands, the higher your chances at busting your knuckles up.

The motor has already been taking apart and rebuilt numerous times, so the inspection values for the clearance via the shims were super off.  We didn't have any of the right shims to put in, but we got a general idea of how to measure the clearance levels between the valves and the camshaft. 

I would say the most difficult part of the task was taking off the camshafts and putting them back on and making sure the timing marks were aligned correctly without damaging the camshafts.  I didn't get to do a lot of wrenching this time around but I got a real good idea of what to expect when I start to work on my bike when I get time to adjust the valves on it.

Taking apart a 1980 Harley Davidson Ironhead Engine

So a couple weeks ago, our class got to take apart a 1980 Harley Davidson Ironhead engine.  I was really looking forward to because my instructor has often preached at how simple and self explanatory it is when it comes to taking apart and rebuilding Harley Davidson engines.  The real issue with the engine that we had was that we had to split apart the crankcase to see what was damaged on the crankshaft.

Often I have heard at how much of a pain it is when it comes to splitting apart crank cases, so this was also another new on hands situation for me to see what its really like for a Harley Davidson engine.  Honestly splitting apart the crankcase was the easiest obstacle compared to taking off the cylinder heads off.

We might have been about an hour passed since we started taking the engine apart and when we got to the point of splitting the case, our instructor used a razor blade to make some leg room to split it apart evenly without causing damage where it seals.  We thought we had all the screws and bolts loose, but apparently one snuck up on us as one bolt was still hiding in the corner of the crankcase where we couldn't see.  My instructor kept commenting about how easily the crankcase usually splits apart in a matter of no time and when we found that last bolt it was a matter of "ooooh, that's why."

I really want to get my hands on a newer model Harley Davidson engine to get a real feeler about how simple theses engines are. Where as it usually takes a full day taking apart and rebuilding a Japanese engine from let's say a sportbike, it only takes about 2-3 hours to disassemble and rebuild a Harley Davidson engine.    

Learning to use the Tire Changer

So I've been on vacation last couple weeks, went to a friend's wedding in Oregon and had to leave everything behind in dear old Georgia.  It was fun while it lasted but it's time to get back into gear, back into work and going back to school.  That said, I've missed quite a bit of motorcycle classes. 

Tonight our instructor showed us how to use the tire changer/tire machine, or whatever the correct term is.  The same ones most major commercial shops use anyway.  Previously I've only known how to take a tire off a rim using the youtube method.  I call it the youtube method because that's how me and a few of my friend's learned how to take our tires off the less costly way using a two by four and some good ole muscle leverage against a ledge.   Also known as the not-so-efficient method, but definitely cost effective if done without damaging the rim itself.

Any who, we started with a wheel and tire from a dirtbike, a Honda CRF 250 to be exact.  Before we started, our instructor told us we would find out why changing out tubes and tires from dirtbike wheels is a pain in the ass, and therefore we would soon find out ourselves.

It was a bit of a process taking the tire off the rim as it also contains the tube, a bead lock, and the center tire band.  But it was even more difficult trying to put it back together, especially tricky trying to line up the bead lock, the band and the tube all at once.  After our instructor showed us, we all took turns taking the tire off and on individually. 

It was a good learning experience all in all because I plan on buying a new tire set for my bike within the next couple weeks, and I wasn't really looking forward to using the 2x4 method again. 

1994 Harley Davidson Heritage Softail--Transmission Removal

So today in the shop class, our class group removed a whole transmission case from a 1994 Harley Davidson Heritage Softail.  It's a nice looking bike for it's age and with a little bit of work can be turned over for a little bit more profit, if the owner decides to sell anyway.

The bike starts up and runs but it winds real loud and chippy through 1st and 2nd gear almost identical to the sound of a car going in reverse but with more obvious notion that something is wrong.  

It wasn't too much of a process to remove the transmission itself but more so trying to get to it.  We had to take the exhaust pipes off with all of the bolts, the primary drive casing, and some of the bottom suspension components to make room for a clean removal.  One thing we noticed while in the process was the ball bearings around the input shaft was half broken and busted, and we assumed the rest of the ball bearing pieces were located inside the transmission case itself. 

Once we got the transmission out of the frame, we split the casing and noticed some of the gear teeth were chipped and broken off.  This is the result of the ball bearing breaking and busting loose.  Kind of like throwing a bag of marbles into a food blender.  The result, noisy and not too pretty to say the least.   Like a dominoe effect, once one thing goes, everything else goes with it.  There's no such thing as the weakest link on a motorcycle as everything works in conjunction with each other.

The transmission is rebuildable with new ball bearings and new gears to replace, but it might cost a decent amount of money at new retail pricing, so we might see about getting a cheaper used transmission to put it in.  The good thing about it is that it doesn't take too long to put back into the frame and in running order, and that the frame and engine is compatible with other Harley Davidson models.



   

My Love for Riding Motorcycles

I've been wanting to get a crotch rocket for the longest since I was a kid. I remember when I was 14, me and my buddies would be looking through cycle trader to look at all the available candy.  We had a set plan that we would get jobs and work until we saved up enough money on our own to buy a motorcycle.  We figured since you have to be 16 to get a license, that we would save up an adequate amount to buy what we wanted.  But of course as years went by, some of us including I procrastinated on saving up.  It was either loaning the money out or buying video games. 

About 3-4 of my friends all got bikes in the summer of 2011.  They either sold their cars, or saved up.  I had just bought a car prior 4 months until I finally gave in and decided to trade my car for a motorcycle.  This was right in the beginning of winter as well of December.  Everyone but my friends thought I was crazy for trading my only piece of transportation for a better love to ride instead.  But I didn't care about the cold or the fighting temperatures.  My hunger to ride has thirsted for years on end and when the opportunity rose up, I left no hesitation to go all in on the deal.  I didn't care thought what others thought, I wanted to ride for my own happiness.  And even if it was 30 degrees or below, I had fun riding either way.   

There is no better feeling in the world to me than riding my bike, other than jumping out of an airplane which I hope to do in the near future.  But when it comes to motorcycle riding, especially at high speeds, every stress and mingle just seems to disappear for a moment's notice.  Driving a regular car for transportation just seems boring to me and not as life fulfilling as riding a motorcycle.  Almost like a airplane on wheels to me, except with limitations of course.  If you haven't rode a motorcycle before, you're definitely missing out on 2-wheels.   

If I won the lottery...ZX-10R?

Let's face it, if we won the lottery you probably would buy everything and anything.  New car, new house, clothes, jewelry, anything you dreamed of anyway.  But for me, as an avid motorcycle rider all season long, I'd buy a motorcycle right off the bat before I bought anything else.  If it was for a japanese bike I would jump on and buy a 2013 Kawasaki ZX-10r.  I wasn't too enthralled with the new front end design but it slowly grew on me the last couple months and I like the new design altogether as far as looks go.  The front end reminds me the face of a dragon, maybe that was intentional.

Has a electronically controlled steering damper that automatically adjusts the rider's speed when accelerating and decelerating upon the riding environment and situation.  More linear power delivery with the new engine and chassis design.  New Anti-Lock Braking System (ABS) brings efficient and optimal wheel spin to the rider's control speed.  To help better control corner handling, Kawasaki has implemented slipper type back-torque limiting clutch to avoid wheel kick out and less chances of sliding while downshifting thru a turn.  Happens to me on my own bike when I forget what gear I'm in while taking a corner.

The big 998cc liquid cooled inline 4 cylinder engine proves to be a beast nevertheless.  The new engine design is compact, lightweight and narrow.  Some of these new liter bikes are looking more like 600's nowadays, just right.  Chromoly camshafts, pistons, crankshaft, large intake valves, stronger connecting rods all but contribute to the power of this bike.  If programmed right, the bike itself can top out at 202mph.  That is some ferocious speed.  But hell who need's to go that fast?.... ME!

        

Motorcycle School

So I recently started going to Chattahoochee Technical College for powersports and motorcycle technology, with the end results of hoping to become a certified motorcycle technician.  Most of the motivation really though is to be able to fix my own bikes without having to spend a fortune and a nickle at the local dealership.  After being referred to a local race shop, I was quoted nearly $3,000 to rebuild and remount my 2002 Yamaha R6 engine.  After working at a warehouse for a couple months and getting that quote, that was enough motivation for me to quit my job and look into going to a motorcycle school.  Although getting a job as a technician would be nice, I'd like to buy project bikes, fix and repair and resell for a profit later on in the future when I get to that point.

Since my loans didn't go through this semester, I was only able to afford a couple classes which is better than nothing honestly.  I go to class once a week, 2pm-10pm for two classes back to back.  It's pretty ideal as well because it fits my work schedule for my off day.  It's already been nearly a month and I've learned a good bit per class.  My instructor is pretty great and knowledgeable, and teaches things with a sense of humor all at the same time so you don't catch yourself yawning especially if there's something you don't understand.

My first class is "Intro to Motorcycles," which really is all about motorcycle theory.  It's a good size class with about 20 people in it, and we all pretty much shoot the shit about everything and anything motorcycles.  Almost like a club get together so to speak without the dress code.  We're a big friendly group though with plenty of stories to share, as well as my instructor.  It's really fun though.

My second class is "Motorcycle maintenance." Since I've already mentioned I only go to this class once a week.  My instructor has stated that it'll be mainly about motorcycle service like oil changes, tire change outs, anything relating to bike fluids, and to focus on valve train adjustment.  That's the one thing I'm pretty excited about, because I've haven't a clue where to start when it comes to valve train adjustment.  Because I'm pretty sure my bike with 50k miles definitely needs one.

The last class we had this week, my instructor demonstrated how to change oil on a 2007 Harley Davidson Ultra Glide.  There wasn't much hands on since it was his own bike but the demonstration proved quite to learn from.  Unlike my 1997 Honda CBR600f3 which has a single oil drain plug, where the engine, transmission and clutch share the same oil...My instructor's Harley had 3 different compartments for oil containment which was the primary drive, transmission and the engine itself.  1 quart of oil for the transmission, 1 quart for the primary drive, and 4 quarts of oil for the engine.  I thought that was pretty interesting.  I quickly noted to the professor that it sounds like he's got to spend quite a bit per oil change if he needs 6 quarts of oil compared to my 3.5 quart amount on my bike.  But he mentioned he usually gets a good deal on his oil.

Hopefully next week I'll be able to get more hands on wrenching in the motorcycle shop whether it be changing oil or whatever.  Right now I'm having issues with my charging system on my bike with my stator and rectifier so hopefully I'll be able to get a closer look into it next week.