Group 37 - Beginner Dirt Bike

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Work Proposal:

The combined skills and experience of our group’s members should help us overcome any problems that we may encounter while dissecting the product. We have members with experience in maintenance and repair of products very similar to those we intend to disassemble.

   The reverse engineering process will begin with the dissection of the breaks and shock absorbers of the mini dirt bike. The first step will involve removing these components from the vehicle. Photos should be taken during each step of the removal and dissection of components to aid in reassembly. 
    For the breaks, the linkage connecting the levers/actuators will be removed first, and then the wheel will be removed from the frame by removing the axle. The linkage will require an open ended wrench to loosen the cable tentioner. The axle nuts will require a wrench on both ends of the axle to remove the axel.
   The front and rear shock absorbers will then be removed.  The fasteners at either end of the rear shock absorber use a cotter pin to prevent them from coming loose. These pins will require a set of pliers to remove. Then a wrench on either end of the fastener will be required to remove it from the upper connection point of the rear shock. The front shock absorbers are clamped and bolted in place. A socket wrench can be used to loosen the clamp but the bolt at the top of may be larger than a standard set of sockets will include. A larger adjustable wrench may be required to remove it. As this bolt is removed caution should be taken due to the possibility of releasing pressure inside the shock as well as spilling hydraulic oil contained inside. Once these components are removed from the bike, dissection of their individual components will begin.
    Unfortunately the rear shock does not appear to be serviceable and may be impossible to disassemble without permanent damage. The collars holding the main spring appear to be welded in place. 
   The front shocks have an allen headed plug located in the lower section that should be used to drain the hydraulic oil before disassembly. Caution should also be taken at this point to prevent spilling of oil and potential release of spring pressure. After this is removed the shock should be able to be separated into two pieces.  There is a seal between the two cylinders that make up the main body of the shock. This may require a pair of snap ring pliers to be removed. The internal components should be exposed for analyzation at this point. 
   Once the axle is removed from the wheel, and the wheel removed from the front fork, the outer cover of the drum break should pull off to reveal the internal pieces. The pieces inside the drum should be able to be removed with either a socket wrench or a pair of pliers. 
   The dissection should be complete and the process of analyzing the components can commence. 

Tool list:

Open ended metric wrenches, Metric socket wrench set Large adjustable wrench Needle nose pliers Allen wrench set Phillips head screw driver Flathead screw driver Snap ring pliers