Motorcycle maintenance often requires general tools and special tools.

(1) general tool

The general tools needed for motorcycle maintenance mainly include wrenches, screwdrivers, hammers, pliers, steel rulers, calipers, square rulers, thickness gauges, dial indicators and so on.

① wrench. Wrenches commonly used by motorcycle maintenance workers mainly include open-ended wrenches, ring wrenches, adjustable wrench, socket wrenches, torque wrenches and Allen wrenches, as shown in figure 1-52.

Figure 1-52 wrench

Open-ended wrench is the most common wrench, also called dull wrench. The central plane of its opening forms an angle of15 with the central plane of its body, which can not only adapt to the operation direction of human hands. But also can reduce the requirement for operating space. Its specifications are expressed by the width (mm) of openings at both ends, such as 8 ~ 10, 12 ~ 14, etc. It is usually a complete set of equipment, including a set of 8 pieces and a set of 10 pieces.

The two ends of the ring wrench are annular, and the inner hole of the ring is formed by two regular hexagons rotating concentrically for 30 degrees. When in use, it can be transposed and sleeved after being pulled 30 degrees, which is suitable for operation in narrow occasions. Compared with the open-ended wrench, the ring wrench has high strength and is not easy to slip off when used, but it is inconvenient to put on and take off. Its specifications are expressed in closed dimensions (mm), such as 8 ~ 10, 12 ~ 14, etc. Generally, it is a complete set of equipment, consisting of 8 pieces and 10 piece.

The socket wrench has the same material and ring hole shape as the ring wrench, and is suitable for assembling and disassembling bolts or nuts with narrow positions or requiring certain torque. The socket wrench is mainly composed of socket head, handle, ratchet switch, quick crank, joint and connecting rod. Various handles are suitable for various occasions, and the specifications of commonly used socket wrenches are 10 ~ 32 mm based on the principle of convenient operation or improving efficiency. Many special socket wrenches are often used in motorcycle maintenance, such as spark plug sleeve, hub sleeve, tire nut sleeve and so on.

The opening size of adjustable wrench can be adjusted at will within a certain range, and the use method is the same as that of an open-ended wrench, but the operation of adjustable wrench is not flexible. Its specifications are expressed by the maximum opening width (mm), and commonly used ones are 150mm, 300mm, etc.

Torque wrench is a special tool that can read the applied torque. Its specifications are divided by the maximum measurable torque, and there are two commonly used types: 294N·m and 490 N m. The torque wrench can be used not only to control the tightening torque of threaded parts, but also to measure the initial torque of rotating parts to check the fit and assembly.

The Allen wrench is used to remove the Allen bolt (plug). Its specifications are expressed by the hexagonal relative size S, and there are 13 types with the size of 3 ~ 27 mm. When motorcycle is maintained, M4 ~ M30 hexagonal bolts are disassembled with a set of hexagonal wrenches.

② screwdriver. Screwdriver, also known as screwdriver, screwdriver, screwdriver or screwdriver, is used to tighten or unscrew screws. There are many kinds of it, the common ones are: according to the shape of the head, it is divided into two types: one word and one cross; According to the material and structure of the handle, it can be divided into four types: wooden handle, plastic handle, clamping handle and metal handle. According to the operation form, it can be divided into manual, electric and pneumatic.

There are two commonly used screwdrivers: straight screwdriver and cross screwdriver, as shown in figure 1-53.

Figure 1-53 screwdriver

A word screwdriver, also known as a word screwdriver and a word screwdriver, is used to tighten or loosen screws with a word head. A straight screwdriver consists of a wooden handle, a knife body and a cutting edge. Its specifications are expressed by the length of the cutter body. Commonly used specifications are 100mm, 150mm, 200mm and 300 mm, and the corresponding specifications should be selected according to the width of the screw groove when using.

Cross screwdriver, also known as cross slot screwdriver and cross screwdriver, is mainly used to tighten or loosen cross slot screws, wood screws and self-tapping screws. Its specification is the same as that of a flat screwdriver.

Figure 1-54 Hand Hammer

③ Hand hammer. Hand hammer is also called dome hammer, as shown in figure 1-54. One end of the hammer is slightly curved, which is the basic working face, and the other end is spherical, which is used to knock the concave and convex parts. Specifications are expressed by hammer mass, and 0.5 ~ 0.75 kg is the most commonly used.

(4) pliers. Hand pliers are commonly used tools for motorcycle maintenance workers, mainly including carp pliers, wire cutters, needle-nosed pliers and wire stripping pliers, as shown in figure 1-55.

Figure 1-55 hand pliers

The front part of the pliers head of carp pliers is flat and fine teeth, which is suitable for clamping ordinary small parts, and the middle notch is thick and long, which can be used for clamping cylindrical parts. It can also replace the wrench to screw small bolts and nuts. The cutting edge behind the pliers can cut the metal wire. Because there are two through holes and a special pin on the pliers body, the opening of the pliers can be easily changed during operation to adapt to clamping parts of different sizes, which is the most used hand in motorcycle maintenance. Its specifications are expressed by the length of pliers, generally 165mm and 200 mm

Wire cutters are clamping and shearing tools. Wire cutters consist of pliers heads and pliers handles. The pliers head includes teeth, blades and side openings. Teeth can be used to tighten or loosen nuts; Knife edge can be used to cut the rubber or plastic insulation layer of flexible cord, and can also be used to cut wires and metal wires; Chisels can be used to cut hard metal wires such as metal wires and steel wires. The supporting foot of the wire pliers is fixed relative to the two pliers, so it is not as flexible as the carp pliers, but the cutting effect is better than the carp pliers. Commonly used specifications are 150mm, 175mm and 200mm.

Needle-nosed pliers are also called prosthodontics. Because its head is slender, it can work in a small space and cut small parts with the cutting edge, so it can't use too much force, otherwise the jaw will be deformed or broken. Its specification is expressed by the length of pliers, and the common specification is 160 mm.

Wire stripping pliers are suitable for stripping plastic and rubber insulated wires and cable cores. It consists of a knife edge, a wire pressing port and a clamping handle, and an insulating sleeve with a rated working voltage of 500V V is sleeved on the clamping handle.

⑤ Steel ruler. The steel ruler is made of stainless steel, and the dimensions are engraved on the ruler surface, as shown in figure 1-56.

Figure 1-56 Steel Ruler

The length specifications of steel rulers are generally 15mm, 200mm, 300mm and 500mm4, and its measurement accuracy can only reach 0.2 ~ 0.5 mm generally. If you want to measure the outer diameter or inner diameter of a part with a steel ruler, you must use it with a caliper.

Figure 1-57 Calipers

⑥ Calipers. There are two kinds of calipers: measuring outer diameter and measuring inner diameter, as shown in figure 1-57. Calipers for measuring outer diameter can be used to measure the thickness, width and outer diameter of parts, which are called external calipers. Calipers for measuring inner diameter are used to measure aperture and groove width, which are called internal calipers.

⑦ Square. Square ruler is also called bending ruler, as shown in figure 1-58. Its inner angle and outer angle are perpendicular to each other. The square is used to check the right angle, marking and installation positioning. The size of a square is expressed by the size of its long side and short side. For example, a square of 250mm× 160mm means a square with a long side of 250mm and a short side of 160mm. ..

Figure 1-58 square

8 thickness gauge. Thickness gauge is also called feeler gauge or clearance gauge. It consists of a group of thin steel sheets, one end of which is nailed together, and each steel sheet is engraved with its own thickness, as shown in figure 1-59. Motorcycle maintenance workers often use it to measure the gap between matching parts, or use it to check the flatness error of the workbench table with a level and a height pad. Its working dimensions are generally 0.02 mm, 0.03 mm, ..., 65438 0.0 mm, and its measuring accuracy is 0.065438 0 mm. ..

Figure 1-59 Thickness Gauge

Pet-name ruby vernier caliper. Vernier caliper is a precise measuring tool with simple structure, which can directly measure the inner diameter, outer diameter, length and depth of parts. Vernier calipers are divided into three orders of magnitude according to the measuring accuracy of 0. 10mm, 0.05mm and 0.02 mm, and there are various specifications according to the measuring size range of 0 ~ 125mm, 0 ~ 150mm, 0 ~ 200mm and 0 ~ 300mm. When used, it is selected according to the precision requirements and the size of the parts.

The structure of ordinary vernier caliper is shown in Figure 1-60, which consists of main ruler, auxiliary ruler, claws and fastening screws. The inner and outer fixed claws are made into a whole with the main ruler, and the inner and outer movable claws are made into a whole with the auxiliary ruler (that is, the cursor) and can slide on the main ruler. The scale on the main ruler is metric 1mm, and the scale on the auxiliary ruler is less than metric1mm. When the two jaws are closed, the zero lines on the main ruler and the auxiliary ruler should coincide. When the two jaws are separated, the scribed lines of the main ruler and the auxiliary ruler are relatively staggered. When measuring, according to the dislocation position of the main ruler and the auxiliary ruler, the millimeter integer can be read on the main ruler and the millimeter decimal can be read on the auxiliary ruler. Fastening screws can fix the auxiliary ruler on a certain position of the main ruler for reading.

Figure 1-60 vernier caliper

Attending a percentage ruler. The dial gauge is a measuring tool, and its differential sleeve reading is 0.0 1mm, and its measuring accuracy is higher than that of vernier caliper. According to the purpose, it can be divided into outer dial indicator, inner dial indicator and depth dial indicator, among which outer dial indicator is the most commonly used.

The outside diameter dial indicator is used to measure the outside diameter, length and thickness of parts. According to the measuring range, there are various specifications such as 0 ~ 25mm, 25 ~ 50mm and 50 ~ 75mm.

The outside diameter dial indicator consists of an arch frame, shaft measuring screws, etc. As shown in figure 1-6 1. The screw is a right-handed thread with a pitch of 0.5mm, and there are also screws with a pitch of1mm. One end of the screw is a cylindrical measuring rod, which is installed in the fixing sleeve on the bow frame after quenching and polishing, and its end face is parallel to the measuring surface of the anvil.

Figure 1-6 1 outside dial indicator

One end of the fixing sleeve is connected with the bow frame, and the other end is internally threaded, which can be matched with the screw. So that the screw can move axially at the same time during the rotation process. There are dimension scribes on the outer side of the fixing sleeve, with the spacing of scribes being 1mm, and the scribes on both sides in the middle are staggered by half a grid (0.5mm).

The differential sleeve is sleeved on the fixed sleeve and connected with the shaft measuring screw. When the screw rotates, the differential sleeve can move on the fixed sleeve. On the conical surface of the differential sleeve, there is a circumferential bisector. When the pitch is 0.5mm, it is divided into 50 equal parts; When the pitch is 1mm, it is divided into 100 equal parts, so the screw moves 0.0 1mm axially every time the differential sleeve rotates.

The friction ratchet is installed at the other end of the screw. When the ratchet wheel rotates, it drives the screw to rotate until the measuring surface of the screw is close to the part, and the screw stops rotating. If the ratchet wheel rotates again, it will make a noise, indicating that it has touched the measuring surface and reached the appropriate measuring force.

Dial indicator Dial indicator is the main measuring tool for checking the size and shape errors of parts in parts processing and machine assembly, as shown in figure 1-62. It is often used to measure the flatness and straightness of the surface of parts, the parallelism between two parallel surfaces of parts, the roundness and roundness of circular parts, etc. The range of the dial indicator is 0 ~ 3mm, 0 ~ 5mm and 0 ~10mm. ..

Figure 1-62 dial indicator

The lower end of the measuring shaft is provided with a measuring head. When measuring, when the measuring head touches the measured surface of the part, the measuring shaft can move up and down. Every time the measuring shaft moves 1nm, the pointer makes a full turn, and the scribed line on the dial divides the circumference into 100 equal parts. Therefore, every time the pointer swings, the measuring axis moves by 0.0 1 mm, and the measuring accuracy of the dial indicator is 0.01mm. ..

(2) Special tools

In the process of motorcycle disassembly, inspection and repair, besides general tools, special tools must be used. Correct and proper use of special tools can avoid damage to parts and ensure reasonable and accurate disassembly, adjustment and assembly.

Special tools commonly used in motorcycle maintenance mainly include clutch assembly tool, piston ring clamp, piston pin unloader, piston ring pliers, crankshaft puller, magneto pin unloader, spoke wrench, valve core wrench, spark plug socket wrench, exhaust pipe wrench, piston top dead center measuring tool, stopper, tire pry bar, tubeless tire repair glue gun, etc.

① Clutch assembly tool. When disassembling the motorcycle clutch, it is difficult to complete it without special tools, especially the fastening screws of the pressure plate on the disc clutch cannot be tightened. Commonly used clutch assembly tools are shown in figure 1-63.

Figure 1-63 Clutch Assembly Tool

When assembling, first install the clutch spring in the spring hole seat of the flywheel, put the upper and lower pressure plates, install the positioning mandrel on the lower pressure plate (put the four sides of the positioning mandrel into the four-side holes of the lower pressure plate), install the spline gear sleeve, and then install the driving plate and the upper pressure plate. Screw the bolt into the screw hole of the flywheel pin (at least 5 buttons should be screwed in), rotate the lever compression spring clockwise until the upper pressure plate contacts the end face of the flywheel pin, first install and tighten four screws, then remove the tool, and then install and tighten the other two screws.

② Piston ring clamp. When assembling the cylinder, in order to make the piston combination enter the cylinder smoothly, the piston ring should be compressed first, so that the outer circular surface of the piston ring is flush with the outer circular surface of the piston. The commonly used piston ring clamp is shown in figure 1-64.

Fig. 1-64 piston ring clamp

When assembling, first pull the wrench to open the clamp and cover the outer diameter of the piston ring of the piston combination, then pull the wrench to close the clamp and press the outer circle of the piston ring to make it flush with the outer circle of the piston. Put the cylinder on the piston assembly, push it down to the piston ring and enter the cylinder. Repeat the above actions until all piston rings are installed in the cylinder, then loosen the wrench and remove the piston ring clamp.

Figure 1-65 Piston pin unloader

③ Piston pin unloader. Generally, the piston pin is closely matched with the piston, so it must not be knocked during disassembly to avoid bending and deformation of the connecting rod. The piston pin unloader is shown in figure 1-65.

When disassembling, the support ring is sleeved on the piston, so that the ejector pin enters the inner hole of the piston pin, and the lever is rotated clockwise until the piston pin is completely pressed out.

④ Assemble and disassemble piston ring pliers. When disassembling the piston ring, you must use special tools, and you can't pull it by hand, so as not to break the piston ring or even damage the piston. The assembly and disassembly of piston ring pliers are shown in figure 1-66.

Figure 1-66 Assembly and disassembly of piston ring pliers

When in use, the piston ring is put into the clamping ring, so that the opening of the piston ring is aligned with the top of the clamping handle, and the piston ring can be opened by firmly holding the clamping handle, so that the piston ring can be put into or taken out of the piston ring groove.

⑤ Crankshaft puller. When repairing the engine, the crankshaft assembly of the engine is generally installed in the crankcase by pulling method. Crankshaft puller is shown in figure 1-67.

Figure 1-67 Crankshaft Puller

When in use, the washer is pressed on the end face of the crankcase and screwed on the threaded end of the crankshaft; Pull the jacket with a wrench and the nut with another wrench, so that the crankshaft can slowly enter the crankcase.

⑥ Magneto puller. The commonly used magneto puller is shown in figure 1-68.

Fig. 1-68 magneto puller

When in use, the screw sleeve is screwed into the internal thread of the magneto (left-handed), and the movable rod is pulled, so that the ejector pin is pushed into the central hole of the crankshaft, and the magneto can be detached by pulling the movable rod continuously.

Figure 1-69 spoke wrench

⑦ spoke wrench. The spoke wrench is used to pull the spoke nut to adjust the axial and radial runout of the rim and the spoke tightness. There are circular spoke wrenches and plate spoke wrenches, each with only six openings of different sizes, which are suitable for nuts of various spokes, as shown in figure 1-69.

End spool wrench. Valve core wrench is used to remove tire valve core and repair valve core. It consists of a die, a tap and a wrench. Tap is used to repair the internal thread of the valve, and round die is used to correct the external thread of the valve. Die pitch is 0.8mm, tap pitch is 0.75mm, and wrench square mouth is 2. 1mm, as shown in figure 1-70.

Figure 1-70 Valve Core Wrench

Figure 1-7 1 spark plug socket wrench

Pet-name ruby spark plug socket wrench. The spark plug socket wrench is used to remove the spark plug, as shown in figure 1-7 1.

When in use, the round rod is inserted into the round hole of the sleeve and used as a plate rod. Due to the different specifications and sizes of spark plugs, the sizes of spark plug socket wrenches are also different. See table 1- 10 for the dimensions of various spark plug socket wrenches.

Table 1- 10 spark plug socket wrench specifications (mm)

Attending exhaust pipe wrench. The exhaust wrench is used to remove the exhaust pipe nut, as shown in figure 1-72. The thickness of the exhaust pipe is generally 4mm, and other related dimensions are determined according to the diameter of the exhaust pipe nut.

When in use, that hook head of the exhaust pipe wrench is clam in the groove of the exhaust pipe nut, and the arc surface is close to the outer surface of the exhaust pipe nut, so that the exhaust pipe nut can be loosen by forcibly pulling the tail of the exhaust pipe wrench. You can also hit the tail of the wrench with a hammer to loosen the exhaust pipe nut, and then pull it by hand.

Measuring tool for piston top dead center. The measuring tool for piston top dead center consists of measuring head, sleeve, table clamp screw and dial indicator, as shown in figure 1-73.

Figure 1-72 Exhaust pipe wrench

Figure 1-73 Measuring tool for piston top dead center

When in use, install the sleeve into the spark plug installation hole. The ignition advance angle can be accurately measured with the dial indicator.

Stop. The stopper consists of cylindrical pin, top plate, rivet, hook plate, fixing rod and other parts, as shown in figure 1-74. When tightening the magneto fixing nut and the small sprocket fixing nut, the magneto flywheel and the small sprocket can be fixed with tools, so as to avoid following the rotation and causing difficulty in disassembly.

Figure 1-74 Plug

Punch the tire stem. Manual tire crowbar is used to disassemble and assemble tires of various specifications, and consists of 2 ~ 3 pieces. According to the tightness of tire rim, select the crowbar with appropriate size. There are two types: bent mouth and straight mouth. The handle is round and flat, and it is also cut into strips with spring steel plate and bent and polished, as shown in Figure 1-75.

Figure 1-75 Tire Rod

Glue gun for repairing tubeless tires. When the tubeless tire is punctured (not exploded) by nails or sharp instruments, the rubber bullet can be driven into the perforation with a tubeless tire patching gun, and the perforation can be sealed by the elasticity of rubber itself, so as to achieve high air tightness and withstand enough air pressure without air leakage. Its shape is shown in figure 1-76.

Figure 1-76 Glue gun for tubeless tire repair