Remove and replace motorcycle combustion engine units and components

P3.1. motorcycle technical data

P3.2. removal and replacement procedures 

P3.3. legal requirements

P4 prepare, check and use all the equipment required following manufacturer’s instructions

P5 carry out all removal and replacement activities following:

P5.1. manufacturer’s instructions

P5.2. industry recognised repair methods

P5.3. your workplace procedures 

P5.4. health, safety and environmental requirements

P6 work in a way which minimises the risk of: 

P6.1. damage to other motorcycle systems, units and components

P6.2. contact with leakage and hazardous substances

P6.3. damage to your working environment

P6.4. injury to self and others

P7 ensure replaced combustion engine units and components conform to the motorcycle operating specification and any legal requirements

P8 promptly record and report any additional faults you notice during the course of your work

P9 use suitable testing methods to accurately evaluate the performance of the reassembled system 

P10 ensure the reassembled combustion engine system performs to the motorcycle operating specification and meets any legal requirements prior to return to the customer

P11 ensure your records are accurate, complete and promptly passed to the relevant person(s) in the format required

P12 complete all removal and replacement activities within the agreed timescale

P13 promptly report any anticipated delays in completion to the relevant person(s) 

K3.1. recording removal and replacement information

K3.2. the referral of problems

K3.3. reporting delays to the completion of work

K4 the importance of documenting removal and replacement information

K5 the importance of working to agreed timescales and keeping others informed of progress and delays

K6 the relationship between time and cost

Use of technical information

K7 how to find, interpret and use sources of information applicable to unit and component removal and replacement within combustion engine systems

K8 the importance of using the appropriate sources of technical information 

K9 the purpose of and how to use identification codes

Combustion engine system operation and construction

K10 how combustion engine systems, including two- and four-stroke engines, and their related units and components are constructed and their operation 

K11 electrical and electronic principles associated with fuel and ignition systems, including types of sensors and actuators, their application and operation

K12 how c*ombustion engine systems* and their related units and components are dismantled and reassembled for the types of motorcycle on which you work

Equipment 

K13 how to prepare, test and use all the removal and replacement equipment required

Combustion engine unit and component removal and replacement

K14 how to remove and replace combustion engine system mechanical and electrical units and components for the types of motorcycle on which you work

K15 how to select and fit gaskets, shims, sealants, fittings and fasteners

K16 how to test and evaluate the performance of replacement combustion engine mechanical and electrical units and components and the reassembled system against the motorcycle operating specifications and any legal requirements

K17 the relationship between testing methods and the units and components replaced – the use of appropriate test methods

K18 the properties of jointing and locking materials and when and where they should be used

K19 the manufacturer’s specification for the engine and electrical units and components to be used

K20 how to work safely avoiding damage to other motorcycle systems, units and components, contact with leakage and hazardous substances and injury to self and others

Electrical unit and component operation and construction

K21 how combustion engine electrical units and components are constructed and their operation for the types of motorcycle on which you work

K22 how combustion engine electrical units and components are removed and replaced for the types of motorcycle on which you work

Electrical and electronic principles

K23 electrical and electronic principles associated with combustion engine systems

K24 types of circuit protection and why they are necessary

K25 electrical safety procedures

K26 how electrical circuits work

K27 electric symbols, units and terms

K28 the hazards associated with working on or near high voltage electrical systems

1.1. hand tools

1.2. special workshop tools

1.3. general workshop equipment

1.4. electrical and electronic testing equipment

2 Testing methods are:

2.1. sensory

2.2. functional

2.3. measurement

3 Units and components are:

3.1. mechanical

3.2. electrical

3.3. fluid systems

4 Combustion engine systems are:

4.1. mechanical 

4.2. cooling

4.3. intake and exhaust

4.4. ignition 

4.5. fuel

4.6. lubrication​