Group 17 - Beginner Dirt Bike/CDR
From GICLWiki
Contents |
Overview
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
Table 3
- *See Group 11 for reassembly of frame
VIDEO: Internal Workings of Engine Before Reassembly
| 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 | 
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| 8 | Use 12 bolts to secure casing to engine block | 9 mm Socket Wrench | 15:00 | 4 (multiple bolts of different lengths) | 
|
| 9 | Reattach Carburetor to elbow joint | 9 mm Socket Wrench | 2:00 | 2 | 
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- *Difficulty in Table 3 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 did not run before we dissected or after we reassembled it. However, the reasons changed slightly. Although there was still no fuel, a piece to the carburetor was also missing. In order for the bike to function, we would just need to add fuel and reattach the piece. The piece was returned late and therefore didn't give us adequate time for testing.
Differences between Reassembly and Disassembly
- A major difference between the reassembly and the disassembly is how the pieces fit together. During reassembly we had to search through our labeled bags of bolts to find which fit the best in each hole. We also had several problems with pieces not fitting back in place, such as the case of the engine block; it was difficult to line up a couple of the intricate parts with the correct part of the casing. This required a trial and error type reassembly which was time consuming but ultimately everything was reassembled properly.
- 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. However, the piece was returned.
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.
- To change the position of the oil compartment to aid disassembly.
- To use better connection between the engine block and the transmissions part.
