Remove and replace motorcycle steering, brakes and suspension 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 steering, brakes and suspension units and components conform to the motorcycle operating specification and any relevant legal requirements

P8 record and report any steering, brakes and suspension units and components that do not conform to legal requirements

P9 promptly record and report any additional faults you notice during the course of your work 

P10 use suitable testing methods to accurately evaluate the performance of the reassembled system 

P11 ensure the reassembled system performs to the motorcycle operating specification and meets any legal and rider requirements prior to return to the customer

P12 ensure your records are accurate, complete and promptly passed to the relevant person(s) in the format required

P13 complete all removal and replacement activities within the agreed timescale

P14 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

K6 the relationship between time and cost

K7 the importance of promptly reporting anticipated delays to the relevant person(s) 

Use of technical information

K8 how to find, interpret and use sources of information applicable to unit and component removal and replacement within the steering, brakes and suspension systems

K9 the importance of using the appropriate sources of technical information 

K10 the purpose of and how to use identification codes

Electrical and electronic principles

K11 electrical and electronic principles associated with motorcycle electronic active braking systems, traction control and suspension systems, including types of sensors, actuators and motors

K12 types of circuit protection and why these are necessary

K13 electrical safety procedures

K14 how electrical circuits work

K15 electrical symbols, units and terms

K16 the operation of electrical and electronic control systems 

K17 the hazards associated with working on or near high voltage electrical systems

*

Steering, brakes and suspension system operation and construction

K18 how different steering systems and their related *units and components (including wheels) are constructed and their operation for the types of motorcycle on which you work

K19 how brake systems, including mechanically and hydraulically linked brakes, and their related units and components are constructed and their operation for the types of motorcycle on which you work

K20 how suspension systems and their related units and components are constructed and their operation for the types of motorcycle on which you work

Equipment

K21 how to prepare, check and use all the removal and replacement equipment required

Steering, brakes and suspension system unit and component removal and replacement

K22 how to remove and replace steering, brakes and suspension system mechanical, electrical and hydraulic units and components (including wheels)

K23 how to select and use appropriate gaskets, sealants, seals, fittings, fasteners, locking devices, brake, steering and suspension fluids

K24 how to test and evaluate the performance of replacement steering, brakes and suspension system units and components and how to compare the reassembled system against the motorcycle operating specifications and any legal requirements

K25 the relationship between testing methods and the steering, brakes and suspension system units and components replaced – the use of appropriate test methods

K26 when replacement units and components must meet the original equipment specification (OES) for warranty or other requirements

K27 the manufacturer’s specification for the type and quality of steering, brakes and suspension units and components to be used

K28 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

K29 how to adjust suspension units and components to meet rider requirements

1.1. hand tools

1.2. electrical, electronic and computer-based

1.3. special workshop tools

1.4. general workshop equipment

2 Testing methods are:

2.1. sensory

2.2. functional

2.3. measurement

3 Steering units and components are:

3.1. steering dampers

3.2. head bearings

3.3. steering systems and associated components

3.4. flexible handlebar mountings

3.5. lock stops

4 Brake units and components are:

4.1. brake linings/pads/discs/drums

4.2. hydraulic brake lines/pipes

4.3. brake cables

4.4. brake linkages/rods (this does not include operating levers)

4.5. brake master cylinder/brake caliper

4.6. brake fluid

4.7. electronically controlled active braking systems including servo assistance components

5 Suspension units and components are:

5.1. front forks

5.2. fork seals

5.3. swinging arms

5.4. trailing arms

5.5. dampers

5.6. road springs

5.7. electronic and actively controlled suspension

5.8. suspension link control arms

5.9. wheels and tyres

5.10. suspension fluid