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Overhaul motorcycle mechanical units

URN: IMIMC11
Business Sectors (Suites): Maintenance and Repair - Motorcycle
Developed by: IMI
Approved on: 2021

Overview

This standard is about the bench-based overhaul of motorcycle mechanical units, involving dismantling, assessment, repair, replacement or adjustment of internal components together with re-assembly and testing.  Mechanical units include engines, transmission and driveline systems, steering and suspension.

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 throughout all **overhauling activities**
P2. use suitable sources of technical information to support your **overhauling activities**
P3. assess and prepare all the **equipment** required, following manufacturer’s instructions, prior to use
P4. use the tools and **equipment** required correctly and safely throughout all **overhauling activities**
P5. carry out all **overhauling activities** following:

P5.1. manufacturer’s instructions
P5.2. your workplace procedures 
P5.3. health and safety requirements
P6. work in a way which minimises the risk of: 

P6.1. damage to other components 
P6.2. leakages
P6.3. contact with hazardous substances
P7. ensure your assessment of the dismantled mechanical unit accurately identifies its condition and suitability for overhaul
P8. promptly inform the relevant person(s) where an overhaul is uneconomic or unsatisfactory to perform
P9. use testing methods which comply with the manufacturer’s requirements
P10. correctly adjust the mechanical unit’s components to ensure that they meet the motorcycle operating requirements, when necessary
P11. ensure the overhauled mechanical units and assemblies conform to the motorcycle operating specification and any legal requirements
P12. ensure your overhaul records are accurate, complete and promptly passed to the relevant person(s) in the format required
P13. complete all overhauling activities within the agreed timescale
P14. 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
ing methods
K1. the legal requirements applicable to the motorcycle mechanical units and assemblies overhauled (including road safety requirements)
K2. the health and safety legislation, environmental requirements and workplace procedures relevant to workshop practices and personal and motorcycle protection
K3. your workplace procedures for:

K3.1. recording overhauling activities
K3.2. the referral of problems
K3.3. reporting delays to the completion of work 
K4. the importance of documenting repair information
K5. the importance of working to agreed timescales and keeping others informed of progress
K6. the importance of promptly reporting any anticipated delays to the relevant person(s) 

Equipment
K7. how to prepare and assess the accuracy and operation of all the overhauling and testing equipment required
K8. how to use all the overhauling and testing equipment required

Motorcycle mechanical unit overhauling activities
K9. how to find, interpret and use sources of information on motorcycle overhauling procedures and statutory requirements
K10. how motorcycle mechanical units and assemblies are constructed and their operation
K11. how motorcycle mechanical units and assemblies are dismantled and reassembled
K12. the types and possible causes of faults in motorcycle mechanical units and assemblies and how to identify them
K13. motorcycle operating specification for limits, fits and tolerances and where this information can be sourced
K14. how to assess the condition evident within unit motorcycle sub-assemblies and components
K15. the cost-benefit relationship between the reconditioning, repair and replacement of components within units and assemblies
K16. how to carry out overhauling activities for the type(s) of motorcycle unit on which you work
K17. the relationship between test methodology and the faults rectified – the use of appropriate testing methods
K18. how to test and evaluate the performance of overhauled units against the operating specification
K19. how to interpret test results and make recommendations
K20. how to make suitable adjustments to motorcycle units and components 
K21. how to work safely avoiding personal injury, damage to components, leakage and hazardous substances

Scope/range

1 Overhauling activities are:

1.1. dismantling
1.2. assessment
1.3. repair
1.4. replacement
1.5. adjustment of internal components
1.6. reassembly
1.7. functional testing

2 Mechanical units are:

2.1. engines
2.2. transmission and driveline systems
2.3. steering
2.4. suspension

3 Equipment is:

3.1. hand tools
3.2. special workshop tools
3.3. general workshop equipment
3.4. electrical and electronic testing equipment

4 Testing methods are:

4.1. sensory
4.2. functional
4.3. measurement​

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.

*
*
Adjustments
Examples include, adjustments made to clearances, settings, pressures, tensions, pre-load

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

Assessments
Examples include those for wear, damage, alignment, corrosion, leakage, distortion and balance

Equipment
Examples include hand tools, pullers and presses, measuring instruments, general workshop equipment and special service tools

Functional testing
This refers to any applicable functional tests carried out after overhaul

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.

Testing methods
As prescribed by the appropriate technical information

Links To Other NOS

External Links

Version Number

3

Indicative Review Date

2024

Validity

Current

Status

Original

Originating Organisation

IMI Ltd

Original URN

MC11

Relevant Occupations

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

SOC Code

5231

Keywords

Motorcycle; ATV; overhaul; mechanical; units; assemblies; steering; suspension; engine; transmission; driveline; measure; tolerances; repair; replace; test