Group 21 - Beginner Cruiser Motorcycle - Preliminary Design Review
Preliminary Product Review
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Causes for Corrective Action:
-As we meet the deadline for our first major product review our group can confidently say everything has gone effectively with no issues up to this point in the process. We were successful because we set a solid foundation in gate 1 of how we were going to manage our time, work and roles during the disassembly. It contained realistic goals and tactics that were met by all members and groups involved by our deadlines.
-The disassembly of the motorbike took approximately 8 hours. We started at the front end of the bike and worked our way towards the center (engine). While disassembling the front section, group 22 was disassembling the rear of the vehicle. Once we had both reached the engine both groups worked together. We planned it this way because it was only fair that both groups get a chance with the “heart” of the bike. Also because the engine is the most complex part and combining our expertise would benefit both groups.
-The only potential problem that was of concern was sharing our product with another large group. This could easily have lead to some cooperation and communication issues. As a result of excellent collaboration no issues arose and everything went smoothly. Both groups worked on the bike simultaneously and met deadlines as a team.
-Sharing with another group was actually a positive situation as opposed to a potential problem. It acted as a support group that kept both groups on time and working efficiently. It also allowed us to combine notes, pictures and ideas incase one group forgot the size of a screw or what part was in a picture.
-Overall everything went as the group had planned. Disassembly deadlines were met with pictures and descriptions of all parts. As a group, meetings were productive and free of conflict. The project so far has proceeded very well and more smoothly than predicted, having one of the more complicated products distributed throughout the class. The bike seemed overwhelming at first to some students who have never disassembled motor vehicles prior to this class.
Procedure for Disassembly:
- difficulty ratings go from 1 to 5. 1 describes simple tasks that do not require physical effort or tedious procedure. 5 describes physically straining tasks or difficult processes that must be followed carefully.
Front End:
Tire:
- Remove axle (using 18mm socket) and nut (using 19mm socket), careful to not misplace washers. Remove tire and wheel from front fork by hand.
- Difficulty: 1
Fender:
- Remove 3 nuts with 8 mm socket from 3 bolts through fender and fender bracket, being careful not to lose washers. Bracket will fall from underneath the fender. Lift the fender out of fork by hand.
- Difficulty: 1
Gas Tank (fake):
- Remove 2 nuts with ½ inch socket from bolts welded to support arms underside the tank shell. Be careful not to lose rubber vibration reducing washers.
- Difficulty: 1
Headlight:
- Unclip white plug from engine, unscrew grounding washer (1) (at end of wire) from the engine using a Phillips head screwdriver, and slip wire out of zip ties (2).
- Remove nuts (2) and bolts (2) through bracket on back of headlight using pliers.
- Unscrew, holding screw (1), from back of light with Phillips head screwdriver, pop cover off back of light.
- Difficulty: 1
Throttle Grip:
- Remove screws (2), with Phillips head screwdriver, from plastic clamp throttle casing. Slide apart while holding throttle grip, keep both halve facing upward. Pull out small black plastic piece on top of cable. Twist the throttle grip and remove metal piece at the end of the throttle cable from white plastic.
- Difficulty: 2
Kill Switch:
- Remove screws (2), with Phillips head screwdriver, from clamping metal piece on backside of kill switch casing. Remove black wire from plug and grounding washer screw (1) with Phillips head screwdriver.
- Difficulty: 1
Handle Bar:
- Using Allen key 6mm, remove 4 screws from each other corner of handle bar bracket. Pull top half of bracket off and lift handle bar out. From the underside of the fork plate, remove the two bolts holding on the handle bar bracket (16mm socket).
- Difficulty: 1
Front Fork:
- Using a large vice grip, remove the large nut in the center of the fork plate. Using 17mm socket, remove bolts through top of plate into fork. Lift plate off center steering shaft. Remove the next 2 spacing nuts on the shaft using a vice grip. Take the last largest nut off the shaft, using a vice grip, make sure not loses the ball bearings that are held underneath this last large nut. Lean the bike back and slide the fork out of the frame.
- Difficulty: 1
Back End
To view back half of bike dissection procedure performed by group 22 click on link below.
Engine
Clutch Cover (plastic):
- By gripping the cover firmly, bend sides out so that clips come out of holes in cover. Pull off gently.
- Difficulty: 1
Clutch:
- Using 12 mm socket, remove bolt and washer at end of drive shaft. To pull the clutch off, the chain must be removed. Find the master link, with a flat head screw driver push between pointed clips so that they spread apart. Slide past the first pin in that link. The master clip can be lifted off second pin at this time. Remove chain and slide clutch off of the drive shaft.
- Difficulty: 3
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Pull Start, Flywheel:
- Remove bolts (3) using an 8mm socket. Pull the pull start assembly off of the fly wheel cover. Make sure to remove both halves slowly from each other as coiled spring is under a lot of tension. Remove bolts (4) from fly wheel cover using a 10mm socket. While holding the flywheel firmly remove nut at center of fly wheel using 19mm socket. Pull metal outer piece and white plastic blades from flywheel.
- Difficulty: 4
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Air Filter and Cover:
- Remove wing nut on top of black plastic air filter cover, with your hand, off of the bolt running thought air filter assembly. Slide the cover up and off of the air filter. Next remove the second wing nut from above the air filter. Slide the air filter off of the long bolt. Next unscrew the two screws in the base of the air filter case with a Philips head screw driver. Slide the base of the air filter case up and off the long bolt.
- Difficulty: 2
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Gas Tank:
- Remove small wire hose clamp (1) with hands and slide hose off of gas tank fitting. Remove nuts from bolts apoxied to the tank (3) using pliers. Lift gas tank off of engine.
- Difficulty: 1
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Clutch Bracket Plate:
- Remove bolts (4) and nuts (4) using pliers and 12mm socket to remove the gold colored clutch bracket plate.
- Difficulty: 1
Heat Plate:
- Remove three bolts from the heat plate using a 10mm socket. The heat plate is located underneath the front part of the engine, along the underside of the cylinder.
- Difficulty: 1
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Exhaust:
- Remove nuts (2) from bolts (2) holding the exhaust header to the engine block, using 12mm socket. Remove screws (4) with a Philips head screw driver, from the heat shield around the muffler. Muffler and exhaust slide out of heat shield by hand.
- Difficulty: 1
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Carburetor, Throttle:
- Remove the springs (2) connecting throttle to connection rod using needle nose pliers. Using pliers remove the nut from the bolt running through the throttle assembly. Lift entire throttle assembly off of the carburetor. Remove hose clamp and rubber hose from carburetor. Remove nuts (2) holding carburetor cover and carburetor onto engine, using pliers.
- Difficulty: 2
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Magneto and Spark Plug:
- First pull rubber plug off of the spark plug by hand. Remove bolts (2) holding magneto next to flywheel using 12mm socket. Using a 13/16 socket remove the spark plug from the cylinder.
- Difficulty: 1
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Head, Head Cover, Valve Train:
- Remove bolts (4) holding down head cover using 10mm socket. Lift with hands. Remove bolts (4) holding down entire head assembly using 12mm socket. Lift off with hands. Be careful not to lose push rods. By removing the head you can access the valves and the top of the piston.
- Difficulty: 2
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Crank Cover:
- Remove bolts (6) using 10 mm socket. Using two flat head screw drivers, slowly and gently pry the cover off of the side of the engine. This action allows access to the cam, drive shaft, and lower piston assembly.
- Difficulty: 2
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