Group 17 - Beginner Dirt Bike
Contents |
Gate 1: Request for Proposal
Gate 2: Preliminary Project Review
Gate 3: Coordination Review
Gate 4: Product Reassembly Plan
We worked on the reassembly of our dirt bike with group 11. Our group was in charge of reassembling the engine and group 11 was in charge of reassembling the frame and everything else.
Recommended Tools:
- Wrench/Ratchet Set
- P12 Screwdriver
- Hands
Steps to Reassembling
- *See Group 11 for reassembly of frame
| Step* | Instructions | Tools Required | Time Required | Difficulty | Picture |
|---|---|---|---|---|---|
| 1 | Set left side casing over engine block and screw on 2 Hex Nuts to hold casing on engine block | 18 mm and 14 mm Socket Wrenches | 2:00 | 1 | 
|
| 2 | Put chain gear back using (2) ½” screws | P12 Screwdriver | 1:30 | 2 | 
|
| 3 | Now insert 2 Hex Nuts to completely secure casing onto engine block | 8 mm Socket Wrench | 1:00 | 1 |
|
| 4 | Replace front of transmission block with 4 Nuts and 4 Washers | 10 mm Socket Wrench | 3:00 | 2 | 
|
| 5 | Replace Air Intake elbow joint using 2 8" Screws | P12 Screwdriver | 2:00 | 1 | 
|
| 6 | Set Right Side casing onto engine block | Hands | 20:00 | 5 (piece was offset and wouldn't fit back into place) | 
|
| 7 | Slide Kick Start and Clutch back into place and tighten bolts | 10 mm Socket Wrench | 5:00 | 3 | 
|
| 9 | Use 12 bolts to secure casing to engine block | 9 mm Socket Wrench | 15:00 | 4 (lots of bolts with different lengths) | 
|
| 9 | Reattach Carburetor to elbow joint | 9 mm Socket Wrench | 2:00 | 2 | 
|
- *Difficulty is measured with 1 being easy to reassemble (little effort) and 5 difficult to reassemble (multiple parts and lots of effort).
Post-Reassembly Analysis
How the Product Runs
- Our product ran before we dissected and reassembled it. After reassembly the product did not run anymore. This is due to a missing piece to the Carburetor. To solve this all we should need is replace this piece and our bike should be running again.
Differences between Reassembly and Disassembly
- A major part of reassembly that is different from the disassembly is how the pieces fit together. We had several problems with pieces not fitting back in place. This required a trial and error type reassembly. Also during reassembly we had to search through bags of bolts to find which ones fit into which holes.
- For the most part the same tools were used. The only difference is we didn't have to use needle nose pliers to pull off tight pieces.
- We were almost able to completely reassemble the engine. The only thing that we didn't completely reassemble was the Carburetor because the piece was missing.
Final Recommendations
- To build the bike using the same size bolts and screws. If there was a standard size of bolts and screws it would've been so much faster and easier to reassemble and to disassemble.
