Group 11 - Gate 2

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Causes for Corrective Action

Assessment: While our work and management plans were comprehensive, some parts were not able to hold up to the work we had to do. Here is a list of several of the problems we faced over the past few weeks and how we have or plan to solve them.


In our original management proposal plan we neglected to include a part on Conflict resolution.

a. Problems faced

-Because we had no plan for recourse if someone did not do their work, or show up, there were several times that work was not done for gate 2.

-To keep this problem from hopefully happening in the future we have come up with a conflict resolution.

b. Solution

-We will have group due dates that will be before the actual class due dates for assignments. This will allow for someone else in the group to pick up the work that has not been completed, with enough time to do satisfactory work.

-If someone is not completing their work in a timely manner, the group leader will discuss with them the reasons. If a situation gets too out of hand the matter will be brought up to the course teacher.

-If a group member skips group meeting, they will have a lessened role within the work. They will either be given the duties that no one else will want, or the will be assigned to help another group member. This will be done because of the reasoning that if they are not responsible enough to make it to group meetings, they are not responsible enough to do a large part of the work in a satisfactory way.


Dissection plan

a. Problems faced. -In the original Work Proposal, we had stated that we were going to be coordinating with another group on the project.

-The original idea was that both groups would work on what they could when they came into the lab. Each group would take notes and share it with the other group.

-The proved difficult, because of notes not arriving, or notes not arriving in time for the next group to arrive in the lab.

b. Solution.

-After the first lab day, we split up the bike.

-The group we were working with, group 11, took the engine and transmission to work on.

iii. Our group took the rest of the bike to dissect

-This allowed each of the groups to have some autonomy, but still in the end having to work together in sharing notes and such.


Time line

a. Problems faced.

-Because of sickness and procrastination we had a hard time following our set out timeline.

-Parts of assignments were handed in late to the group leader, who was suppose to be able to have time to proof read them

b. Solution

-The group leader will be assigning a group due date for all assignments. This due date will be several days before the actual class due date.

-This will allow time for the group leader to proof read all assignments, as well as reassign any work that might not have been done.

-Also this will mean that even if a group member submits a part of an assignment late for the group due date, it will still be before the class due date.

-Group due dates will typically be 3 to 4 days before the assigned class due date for all assignments.

Product Dissection Plan

Step Part Pieces
one side panel - (1)8.8 F screw w/ washer

-(2) ½” P1 screws -(1) ¾” P2 screws with rubber and a metal washer -and a hex nut

two front mud guard (3) 8.8 F, ½” screws with ½”D washers
three seat (2) ¾” screws with washers
four chain guard (2) ½” 8.8 F screws with washers
five plastic front guard (1) ½” 8.8F bolt
six gas tank (2) 8.8 F 1” with welded nut & ¾” washer
seven electrical -throttle and kill switch on handlebars

-wiring running throughout bike

eight chain take off master link to remove from bake wheel
nine rear suspension two bolts with washers
ten kick stand -(1) ¾” P2 Phillips screws

-sprin between kickstand and engine

eleven engine block (2) bolts with washer and nut

(for engine block disassembly please see group 17's page

twelve handle bars (4) small bolts
thirteen front fork assembly -(1) large bolt

-ball bearing parts

fourteen front wheel -19 mm nut

-13mm bolt head

fifteen rear wheel -17 mm nut

-15 mm bolt head

sixteen rear suspension arm -14 mm nut

-13 mm bolt head

Dis-assembly process


Is the Product intended to be taken apart easily?

The dirt bike is intended to be taken apart relatively easily. The maker of the bike makes dissection easy so that the bike can be maintained. Many parts were relatively easy to take apart because they are parts that might need to be replaced or fixed in the lifetime of the bike. By making them easy to take apart/off allows for easy access during maintenance.

How easy is each step?

In the disassembly, each step was a main part of the bike we took off. Most steps were relatively easy while others posed a bit of a challenge to us. Each step was to take the bike apart from the front to the back. With 5 being the toughest and 1 being the easiest, this is a rating system we used for each step:

-Seat/Plastic Cover – 2 –Done by other group, rating is what we think the difficulty was

-Engine/Exhaust – 5– Done by other group as well, rating is what we thing the difficulty was

-Handlebars – 3 – Just requires a lot of work, not so much difficult

-Front Forks -3 – Only problem was the large nut we couldn’t get off at first

-Front Wheel Parts – 1 – No considerable problems at all

-Kick Start/Stand - 2 – Not too difficult just a couple easy attachments

-Rear Suspension Spring – 3 – Requires a bit of tough work but nothing too bad

-Rear braking system – 2 – Some small hands work for some of the parts but overall easy

-Rear Wheel from Frame – 4 – Tough when the rear braking system was attached very well

-Cables – 5 – Requires screw driver, screws heads are in poor shape, it was extremely difficult getting the cables detached from the handlebars and such when the screws are beat up

What fasteners are used and why?

Fasteners were used on this bike to ensure that something that is bolted on will in fact stay and not come lose. Half of the dirt bike was held together with metric bolts while the other half was held together with standard. We believe that the bike had such different bolts because of how it was manufactured. In today’s economy, many companies have companies outside of the United States make their parts. Such, the dub-company could have used different bolt measurements then the original company. The bolts that were on the bike varied depending on their position and what they were fastening. The size and length of the bolt was based on its position and assumed stress. The bolts throughout the bike needed to handle the assumed stress without shearing or bending, thus making riding dangerous. It is for this reason that the bolts on the bike ranged from a 6mm Alan wrench bolt, to the large bolt found on the front forks. The length of the bolt depended on the thickness of the material that it was securing. Several of the bolts used washers, while others did not. These washers were used to spread the pressure out over a greater surface, thus not denting or ripping through the material. Many of the nuts used on the bolts were self locking, meaning that they would not loosen until a certain amount of torque was applied to them. These were used because the pressure a bolt would go through would not cause it to loosen and make the secured parts rattle. In the case of a dirt bike, a loose part can cause the bike to not function correctly or a decrease in efficiency. Thus the bolts and nuts used were chosen to reduce the likelihood of failure.

Are specific tools required?

While not specific tools are required, the correct sized tools are required. The lack of different sized tools made it difficult to take some parts off of the front forks as well as the front tree assembly itself. We were forced to use large locking pliers instead of a socket wrench or crescent wrench. This time we had no problems but with another dirt bike, we could have stripped the upper nut on the front tree assembly.