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Diagnose and rectify motorcycle combustion engine and component faults

URN: IMIMC07
Business Sectors (Suites): Maintenance and Repair - Motorcycle
Developed by: IMI
Approved on: 2021

Overview

This standard is about diagnosing and rectifying faults occurring in the motorcycle combustion engine mechanical, electrical and hydraulic and fluid systems. This standard does not include gearbox, clutch and final drive which are covered in another standard.

In this standard the term ‘motorcycle’ includes motorcycles, scooters, mopeds and motorcycle-derived vehicles with three or four wheels (such as quad bikes) on which the rider sits.

Performance criteria

You must be able to:

P1. use suitable personal protective equipment and motorcycle coverings (where applicable) when using diagnostic methods and carrying out rectification activities
P2. ensure the motorcycle and the work area is safe prior to commencing with any diagnostic or rectification activity
P3. support the identification of faults by reviewing motorcycle: 

P3.1. technical data
P3.2. appropriate diagnostic test procedures
P4. prepare and check all the required equipment following manufacturer's instructions prior to use
P5. use diagnostic methods which are relevant to the symptoms presented 
P6. collect sufficient diagnostic information in a systematic way to enable an accurate diagnosis of combustion *engine* system faults
P7. correctly interpret test results from engine mechanical, electrical, electronic, hydraulic, fluid and lubrication systems
P8. accurately identify and record any system deviation from acceptable limits 
P9. ensure your assessment of dismantled sub-assemblies, units and components accurately identifies their condition and suitability for repair or replacement 
P10. promptly inform the relevant person(s) where repairs are uneconomic or unsatisfactory to perform
P11. use the equipment *required, correctly and safely throughout all *diagnostic methods and rectification activities
P12. carry out all rectification activities following: 

P12.1. manufacturer's instructions
P12.2. industry recognised repair methods
P12.3. your workplace procedures 
P12.4. health, safety and environmental requirements
P13. work in a way which minimises the risk of: 

P13.1. damage to other motorcycle systems, units and components
P13.2. contact with leakage or hazardous substances
P13.3. damage to your working environment
P13.4. injury to self and others
P14. ensure all repaired and replaced units and components conform to the motorcycle operating specification and any legal requirements
P15. record and report any engine systems that do not conform to legal requirements
P16. correctly adjust units and components to ensure that they operate to meet system requirements, when necessary
P17. promptly record and report any additional faults you notice during the course of work 
P18. use testing methods which are appropriate for assessing the performance of the rectified system 
P19. ensure the rectified combustion engine system performs to the motorcycle operating specification and any legal requirements prior to return to the customer
P20. ensure your records are accurate, complete and promptly passed to the relevant person(s) in the format required
P21. complete all system diagnostic and rectification activities within the agreed timescale
P22. promptly report any anticipated delays in completion to the relevant person(s) 

Knowledge and Understanding

You need to know and understand:

​Legislative and organisational requirements and procedures
K1. the health and safety legislation, environmental requirements and workplace procedures relevant to workshop practices and personal and motorcycle protection when diagnosing and rectifying combustion engine faults
K2. legal requirements relating to the motorcycle (including road safety and environmental requirements)
K3. your workplace procedures for:

K3.1. recording diagnostic and rectification activities
K3.2. the referral of problems
K3.3. reporting delays to the completion of work
K4. the importance of documenting diagnostic and rectification *information
K5. the importance of working to agreed timescales and keeping others informed of progress
K6. the relationship between time, costs and productivity
K7. the importance of promptly reporting anticipated delays to the relevant person(s) 

Electrical and electronic principles
K8. electrical and electronic principles associated with *combustion engine systems, including types of sensors and actuators, their application and operation
K9. how electrical and electronic engine systems operate, including electrical component function, electrical inputs, outputs, voltages, oscilloscope patterns and digital principles
K10. the interaction between electrical, electronic and mechanical components within motorcycle combustion engine systems
K11. electrical symbols, units and terms 
K12. electrical safety procedures
K13. the hazards associated with working on or near high voltage electrical systems and components

Use of diagnostic and rectification equipment *
K14. how to prepare and check the accuracy of diagnostic testing *equipment
K15. how to use diagnostic and rectification equipment for combustion engine mechanical, electrical, electronic, hydraulic and fluid systems, specialist engine repair tools and general workshop equipment

Combustion engine electrical faults, their diagnosis and correction
K16. how two- and four-stroke combustion engine mechanical, electrical, electronic, hydraulic and fluid systems are constructed and operate, are dismantled and reassembled
K17. how combustion engine components interlink, including multiplexing
K18. the types and causes of combustion engine mechanical, electrical, electronic, hydraulic and fluid system unit and component faults and failures 
K19. combustion engine mechanical, electrical, electronic, hydraulic and fluid unit and component replacement procedures, the circumstances which will necessitate replacement and other possible courses of action
K20. how to find, interpret and use sources of information on combustion engine electrical and electronic operating specifications, diagnostic test procedures, repair procedures and legal requirements
K21. motorcycle operating specifications for limits, fits and tolerances relating to combustion engine mechanical, electrical, electronic, hydraulic and fluid systems for the types of motorcycle on which you work
K22. how to select and carry out the correct diagnostic testing method *
K23. how to assess and interpret results of the condition of components 
K24. how to make cost effective recommendations for rectification
K25. how to carry out *rectification activities in order to correct faults in the combustion engine mechanical, electrical, electronic, hydraulic and fluid systems
K26. the relationship between test methodology and the faults rectified – the use of appropriate testing methods

Scope/range

1 Faults occur within the combustion engine:

1.1. mechanical system
1.2. electrical system
1.3. electronic system
1.4. hydraulic and fluid systems

2 Diagnostic and testing methods are:

2.1. sensory
2.2. functional
2.3. measurement

3 Equipment is:

3.1. diagnostic and rectification equipment for combustion engine mechanical systems
3.2. diagnostic and rectification equipment for combustion engine electrical systems
3.3. diagnostic and rectification equipment for combustion engine electronic systems
3.4. diagnostic and rectification equipment for combustion engine hydraulic and fluid systems
3.5. specialist repair tools
3.6. general workshop equipment

4 Rectification activities are:

4.1. dismantling
4.2. replacement of units and components
4.3. adjustment of units and components
4.4. repairs to wiring and connectors
4.5. re-programming motorcycle systems
4.6. reassembly
4.7. functional testing

5 Combustion engine systems are:

5.1. mechanical
5.2. cooling
5.3. intake and exhaust
5.4. ignition
5.5. fuel
5.6. lubrication 
5.7. engine management​

Scope Performance

Scope Knowledge

Values

Behaviours

Skills

Glossary

This section contains examples and explanations of some of the terms used but does not form part of the standard.

*
*
Agreed timescales
Examples include manufacturer’s recommended work times, job times set by your company or a job time agreed with a specific customer

Diagnostic information
This relates to mechanical condition, including wear, run out, pressures and compressions, flow, leakage and electrical measurements such as voltage and pulse displays, electronic systems data, including fault codes, sensor measurements and control unit outputs and/or signals

Engine Area
Engine mechanical, cooling systems, electronic ignition, petrol fuel injection, lubrication, engine management systems, emissions control systems, starting and charging

Engine and component faults
These are faults that require a two or more-step diagnostic activity using a prescribed process or format to identify the cause

Functional diagnostic methods
Examples include intake system balance, exhaust and emissions, performance testing and road testing where relevant

Hydraulic and fluid systems
These are fuel, oil, lubrication and cooling

Motorcycles
In this standard the term ‘motorcycle’ includes motorcycles, scooters, mopeds and motorcycle-derived vehicles with three or four wheels (such as quad bikes) on which the rider sits.

Recommendations
Examples include servicing, dismantling for further inspection and test, repair and replacement

Sensory diagnostic methods
These may include looking, listening, smelling and touching for heat.

Links To Other NOS

External Links

Version Number

3

Indicative Review Date

2024

Validity

Current

Status

Original

Originating Organisation

IMI Ltd

Original URN

MC07

Relevant Occupations

ATV Diagnostic Technician, Engineering, Motorcycle Diagnostic Technician, Vehicle Trades

SOC Code

5231

Keywords

Motorcycle; rectify; diagnose; combustion; engine; ATV; component; faults; units; starting; charging; electronic; electrical