COMPETENCY BASED LEARNING MATERIAL

Sector: Automotive and Land Transport Sector

Qualification: Motorcycle/Small Engine Servicing NC II

Unit of Competency :
Read, Interpret and Apply Specifications and Manuals

Module Title:
Reading, Interpreting and Applying Specifications and Manuals

Technical Education and Skills Development Authority

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Learning Guide Procedure U. Salvatera
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 HOW TO USE THIS COMPETENCY-BASED LEANING MODULE

Welcome To The Module: “Reading, Interpreting, And Applying Specification

And Manuals”. This module contains training materials and activities for you
to complete.
The Unit Of Competency, Read, Interprete and Apply Specification And
Manuals contains the knowledge, skills and attitudes required for
Motorcycle/Small engine Servicing course. This is one of the common
module for National Certificate level II (NC II)
You are required to go through a series of learning activities, n order
to complete each learning outcome there are information sheets, operation
sheet and job sheet. Reference materials for further reading to help you
better understand and required activities on you own and answer the self-
check at the end of each learning outcome. Get the answer form your
instructor and check your work honestly. If you have question, please don’t
hesitate to ask the facilitator for assistance.

RECOGNITION OF PRIOR LEARNING

You may already have some or most of the knowledge and skills
covered in
this module because you have:
1. Been working for sometime
2. Already completed training in this area
If you can demonstrate to your trainer that you are competent in
particular skill or skills, talk to him/her about having them formally
recognized so you won’t have to do the same training again. If you have
qualifications or certificates of competency are still relevant of this module,
they may become part of evidence you can present you RPL. If you are not
sure about the currency of your skills, discuss it with you trainer.
After completing with this module ask your trainer to assess your
competency. Result of your assessment will be recorded in your competency
profile. All the learning activities are designed for you to complete at your
own pace.
Inside this module you will find the activities for you to complete and at
the back are the relevant information sheets for each learning outcome.
Each learning outcome may have more than one learning activities.
At the end of this module is a Learner’s Diary. Use this diary to record
important dates, jobs undertaken and other workplace events that will assist
you in providing further details to your trainer or an assessor. A Record of
Achievement is provided for you by your trainer to accomplish once you
complete the module.

This learning material was prepared to help you achieve the required
competency in working team environment. This will be the source of
information for you to acquire the knowledge and skills in this particular

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trade independently and at your own pace with minimum supervision or
help from your instructor
In doing these activities to complete the requirements of this module,
please be guided by the following:

 Talk to your trainer and agree on how you will both organize the
training under this module. Read through module carefully. It is divided into
sections which cover all skills and knowledge you need to successfully
complete.
 Work through all information and complete the activities in each
section. Read information sheets and complete the self-check provided in
this module.
 Most probably your trainer will also be your supervisor or manager.
He/she is there to support you and show you the correct way to do things.
Ask for help.
 Your trainer will tell you about the important things you need to
consider when you are completing the activities and it is important that you
listen to take notes.
 You will be given plenty of opportunities to ask question and practice
on the job. Make sure you practice your new skills during the regular work
shifts. This way you will improve both your speed and memory and also your
confidence.
 Talk to more experienced work mates and ask their guidance.
 Use self-check question at the end of each section to test your own
progress.
 As you work through the activities, ask for written feedback on your
progress. Your trainer keeps feedback/ pre-assessment reports for this
reason. When you have completed this learning material and feel confident
that you have the sufficient knowledge to assess you. The results of the
assessment will be recorded in your competency achievement record.

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 MODULE CONTENT

QUALIFICATION : MOTORCYCLE/SMALL ENGINE SERVICING NC II

Unit of Competency: Read, Interpret and Apply Specification and
Manuals
Module Title: Reading, Interpreting and Applying Specification
and Manuals
INTRODUCTION:
This unit deals with identifying, interpreting, and applying service
specification manuals, maintenance procedure manuals and periodic
maintenance manual
NOMINAL DURATION:
LEARNING OUTCOMES
After completing this module, you should be able to:
1. Identify and access manual/specification
2. Interpret manuals
3. Apply information in manual
4. Store Manuals

ASSESSMENT CRITERIA:
1. Appropriate manuals are identified and accessed as per job
requirements.
2. Version and date of manual is checked to ensure correct
specification and procedure are identified.
3. Relevant sections, chapters of manuals/specifications are located in
relation to the work to be conducted
4. Information and procedures in the manual are interpreted in
accordance to the industry practices.
5. Manual is interpreted according to job requirements
6. Work steps are correctly identified in accordance with the
manufacturer specification
7. Manual data is applied according to the given task
8. All correct sequencing and adjustment are interpreted in
accordance with the information contained on the manual or
specification
9. Manual or specifications are stored appropriately to ensure
prevention of damage, ready access and updating of information
when required in accordance with the company requirements

LEARNING OUTCOME # 1 1. Identify and access manual/

specification

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 CONTENTS:
o specification manual
o Repair manual
o Maintenance Procedure Manual

ASSESSMENT CRITERIA:
The learning outcome stated above is attained if you can demonstrate the
following:
1. Appropriate manuals are identified and accessed as per job requirements.
2. Version and date of manual are checked to ensure correct specification and
procedure are identified.

CONDITIONS: Students /trainees must be provided with the following:

1. Supplies/materials
manufacturing specifications
repair manual
maintenance manual
2. Instructional materials
modules,
CDs, Slides
METHODOLOGY:
1. Lecture/demonstration
2. Dualized
3. Distance learning
ASSESSMENT METHODS: Written /oral examinations
1. Direct observation
2. Interview

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 LEARNING EXPERIENCES

LEARNING OUTCOME NO. 1: Identify and access

manual/specification
Learning Activities Special Instruction

Read: Information Sheet 4.1- If you have some problem on the

1 content of the information sheet, don’t
specification manual hesitate to approach your facilitator.
If you feel that you are now
Answer Self Check No. . 4.1-1 knowledgeable on the content of the
information sheet, you can now answer
self-check provided in the module.
Compare your answer to the key. If you
got 100% correct answer on the self-check
. 4.1-1

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 INFORMATION SHEET 4.1-1

Specification Manual
Objectives:
At the end of the lesson, you should be able to:
1. Follow manufacturer’s manual.
Introduction:
This unit deals with identifying, interpreting, and applying service
specification manuals, maintenance procedure manuals and periodic
maintenance manual
All over the years, the vehicles you will be working on as a technician
become more and more complicated. In years past, a mechanic or a
technician could keep all the repair information they needed in their head.
Now, those days were gone. One of the important tools as a technician must
have is the correct, up-to-date service information for the vehicle you are
working on. A technician must learn to read and understand service
information. This module will present the different types of service
information used by the technician.

MANUFACTURE’S SERVICE MANUAL

Manufacturer’s service manual or sometimes its called a shop manuals, are

written by the motorcycle manufacturer for the technicians in their
dealership. A shop manual covers one model and one year of a vehicle in
great detail, sometimes it is printed in a number of volumes. Shop manuals
are the best source of detailed service information for specific motorcycle.

Shop manuals / service manuals are necessary to obtain the desired

specification for specific job. It also provide drawings and photograph to
show where and how to perform a certain procedure in a particular car you
are working on. Special tools or instrument are listed and shown when they
are required. Precautions were given to prevent injury and damage to the
parts.

Motorcycle manufacturers publish a service manuals or set of manuals for

each model and year of their cars. These manuals provide the best and most
complete information for their cars. Although the manuals from different
manufacturer vary in presentations and arrangement of topics, all service
manuals are easy to use after you become familiar with their organizations.

Shop manuals are divided into a number of sections, each covering a

different aspect of the vehicle. The beginning sections commonly provide a
vehicle identification and basic maintenance information. The remaining
sections deals with each different vehicle system. And each section has an
index indicating more specific areas of information
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 Typical Cover of A Service Manual

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 Table of Contents

The shop manuals contain three basis types of information. First, there
is diagnostic or troubleshooting information. Second, they contain a step-by-
step repair procedure. Third, there a specification charts.
DIAGNOSING OR TROUBLESHOOTING INFORMATION
Probably the most valuable type of service information comes from the
troubleshooting or diagnosing guides. These are designed to help the
technician save time in identifying and solving problems.
PROCEDURE INFROMATION
Procedure information gives the steps to follow in doing a repair job. The
procedures are usually numbered in a step-by-step order.
SPEFICIFICATION
Specifications are included as part of the service manual. Specifications are
technical data, numbers, clearances and measurements used to diagnose
and adjust automobile components. Specifications can be referred to as
specs. They are usually considered precise measurements under standard
conditions. Examples of specifications include valve clearances, spark plug
gaps, tire pressure, number of quarts of oil, ignition timing and size of
engine.
TYPES OF SPECIFICATIONS
General Engine Specification – This specification identify the size and style
of the engine. They include cubic inch displacement, engine codes, fuel
system settings, bore and stroke, horsepower, torque, compression ratio,
and normal oil pressure.
Tune-Up specifications – This specification helps identify adjustments
necessary for tune-up on the vehicle. This includes spark plug gap, firing
order, degrees of ignition timings, fuel system settings and fuel pump
pressure.
Capacity Specifications –This specification include to identify the capacity of
different fluids on the vehicle. This includes cooling capacity, number of
quarts of oil, fuel tank size, transmission transaxle capacity, and rear axle
capacity.
Overhaul and Maintenance Specifications – This specification used to aid
technician in servicing the vehicle. This include distributor advance at
different speeds, valve seat angles, valve stem clearance, piston
measurements, ring end gaps, bearing clearances, shaft end play and many
more. This specification help the technician determine how much wear has
occurred. The mechanic is then able to decide whether or not to replace the
component in question. Usually maximum or minimum clearances are given
for this purpose.

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Operational Specification – This specification tell how the vehicle is to
operate, what type of oil to use, and so on. Some of them are found in the
owner’s manual. Other specification includes tire inflation, type of gasoline

to use, tire size and general information for the operator of the vehicle.
Torque Specification – It is important to torque each bolt or nut correctly
when replacing or installing a component on the automobile. Torque
specifications are used for this purpose. This torque specification should be
used in place of any standard bolt and nut torque specification.

OWNERS MANUAL
An owner’s manual or an operator’s manual is a booklet that comes with a
new motorcycle. This manual usually explains how to operate the
automobile’s control and accessories. In addition the owner’s manual
provides a great deal of technical information that can be useful to the
technician.

In an owner’s manual a vehicle maintenance procedure is provided so that

the owner will know when to get needed service.

A cover and a table of contents of a typical owner’s manual

AFTERMARKET REPAIR MANUAL

An aftermarket repair manual is most often used by the
technician at independent repair shops. This manual is called an
aftermarket because it is published by independent publisher and
not by the car manufacturer. Like the shop manual. This contains
information on troubleshooting, specifications and step-by-step
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 repair procedures. The main difference is that they cover many
different car models and years instead of just one. Because they
are covering more models and years, they typically cover topics
in less detail
(Vehicle Identification Number)

The official vehicle identification number is needed to

identify the exact type of vehicle being worked on. The VIN is
also used for title and registration purposes. It is normally
stamped on a metal tab that is fastened to the instrument panel
close to the wind shield. Each manufacturer has assigned a VIN
to each vehicle manufactured. Each VIN number represents
different data. The following information can be determined be
reading the VIN number.
 The country by which the vehicle was manufactured or the world
manufacturer
 The corporation and division
 Model or series of the vehicle
 Model year
 Body style
 Check digit
 Engine type
 Factory or plant code
 Vehicle serial number

SELF CHECK 4.1-1

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 Multiple Choice:

Direction:

Choose the right answer among the given choices by

writing the letter of it in the space provided for.
1. Which of the following information is not included in a service
manual?
a. specification
b. sales and promotion
c. disassembly procedures
d. detailed theoretical information
e. vehicle colors and styling

2. Which of the following information is usually shown as

measurement,
clearances and numbers?
a. Procedure Information
b. Troubleshooting information
c. specification information
d. overhaul procedures
e. special tool

3. Specification that include spark plug gap, ignition timing

and carburetor adjustment are called?
a. Tune-up specification
b. Capacity specification
c. Overhaul and maintenance specification
d. Procedure specification
e. None of the above

4. Specification that show bearing clearance, and ring gaps

are called?
a. Tune-up specification
b. General engine specification
c. Capacity specification
d. Overhaul and maintenance specification
e. Troubleshooting specification

5. Torque specification are identified as:

a. Torque on nuts and bolts
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 b. Engine torque at certain speeds
c. Torque applied to the crankshaft during operation
d. Torque applied to the generator
e. Torque applied on turns
6. Technician A says that plug gaps, clearances and torque on
bolts
cannot be found in a service manual. Technician B says
overhaul
procedures in the sales literature. Who is right?
a. A only
b. B only
c. Both A and B
d. Neither A or B
7. Technician A says that diagnosis information can be found in
the service
manuals. Technician B says that diagnosis information can be
found only in literature obtained from the manufacturer. Who
is right?
a. A only
b. B only
c. Both A and B
d. Neither A or B
8. Technician A says that the VIN does not include any
information about the engine in the vehicle. Technician B
says that the VIN does not include the vehicle serial number.
Who is right?
a. A only
b. B only
c. Both A and B
d. Neither A or B
9. When looking for the VIN on the vehicle, technician A says
it can be found on the dashboard on the driver’s side.
Technician B says it can be found in the owner’s manual.
Who is right?
a. A only
b. B only
c. Both A and B
d. Neither A or B

ANSWER KEY 4.1-1

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 1. B
2. C
3. A
4. D
5. A
6. D
7. A
8. D
9. A

LEARNING OUTCOME # 2 Interpret manuals

CONTENTS:
o Applied information manual
o Identification of symbols used in manual

ASSESSMENT CRITERIA:
The learning outcome stated above is attained if you can
demonstrate the following:
 Relevant sections, chapters of manuals/specifications
are located in relation to the work t be conducted
 Information and procedures in the manual are
interpreted in accordance to the industry practices.

CONDITIONS: Students /trainees must be provided with the following:

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 2. Supplies/materials
- manufacturing specifications
- repair manual
- maintenance manual
- periodic maintenance manual
3. Instructional materials
- reference books
- professional emergency
- learning guides
- modules,
CDs, VHS tapes, transparencies
METHODOLOGY:
4. Lecture/demonstration
5. Dualized
6. Distance learning
ASSESSMENT METHODS: Written /oral examinations
3. Direct observation
4. Project method
5. Interview

LEARNING EXPERIENCES

LEARNING OUTCOME NO. 2: Interpret manuals

Learning Activities Special Instruction

Read: Information Sheet 4.2-1  If you have some problem on the

Applied information manual content of the information sheet,
don’t hesitate to approach your
facilitator.
 If you feel that you are now
Answer Self Check No. . 4.2-1 knowledgeable on the content of the
Applied information manual information sheet, you can now
answer self-check provided in the
module.
Read: Information Sheet 4.2-2 Compare your answer to the key. If you
Identification of symbols used got 100% correct answer on the self-
in manual check . 4.2-1/2 diagnosing or
troubleshooting information

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 Answer Self Check No. . 4.2-2

INFORMATION SHEET 4.2-1

Applied information Manual

A manufacturing specification contains all the information that

is needed to make the product. It describes the stages of
manufacture and the materials needed, using flowcharts, diagrams,
notes and samples. ... A manufacturing specification is done once
the final product has been developed.
 Engine:
 Type:
 No. of Strokes: Engines in motorcycles discussed on this site
are all four-stroke. There are two-stroke engines as well. Also,
don't confuse four-stroke with four-cylinder or two-stroke with
two-cylinder. They are totally different. The four strokes in a
four-stroke engine are defined as follows:
 Stroke 1 - Intake valve(s) open, piston moves down, sucking in
the air/fuel mixture.
 Stroke 2 - All valves closed, piston moves up, squeezing the
mixture.

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 Stroke 3 - All valves still closed, spark plug ignites the fuel/air
mixture, pushing the piston down.
 Stroke 4 - Exhaust valve(s) open, piston moves up, blowing the
old charge out the exhaust valves.
 A short version is Suck, Squeeze, BANG, and Blow.
 Cooling: An engine can be liquid-cooled by running coolant
through the engine and exchanging the heat via a radiator like a
car. It can also be air-cooled by airflow over fins on the engine.
Another variation is oil-cooling where engine oil is circulated in
the engine and its heat exchanged by a small radiator. There are
even oil/air/fan cooling systems.
 Valves: Valves are used as mentioned above. There may be one
or more valves used for intake and exhaust. The specs may
indicate how many valves are used per cylinder or for the whole
engine. Terms such as SOHC (Single OverHead Cam) and DOHC
(Double OverHead Cam), etc. are used to indicate how the
valves are opened and closed. There are other methods to
operate the valves as well.
 Number of Cylinders: Engines can have one to six cylinders.
 A single-cylinder engine, sometimes called a thumper, is used in
small bikes.
 Most bikes have engines with two-cylinders arranged in many
configurations including: V-twin where the cylinders are spaced
at a particular angle to each other; Parallel twin where the two
cylinders are right next to each other in a vertical position; and
Flat-twins where the two cylinders are opposed such as in BMW
Boxers.
 Engines may have more than two cylinders such as: Triples
where three cylinders are lined up next to each other in a
vertical position; In-line fours similar to a triple except with
another cylinder added; V-4 engines such as used in Honda
ST1300; V-6 engines such as used in Boss Hoss; Flat-six engines
such as used in Honda Gold Wing 1500/1800s.
There are other engines not described.
 Displacement: Displacement is the volume displaced in the
cylinders of an engine as the pistons move from their bottom
position to their highest position in the cylinders. Displacement
is measured in either cubic centimeters (CC) or cubic inches (CI).
 Bore and Stroke: Bore is the diameter of the cylinder in the
engine in which a piston moves up and down. Stroke is the
distance that the piston moves up and down inside the cylinder.

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 Fuel System: Either carburetor(s) or fuel injection is used to
control the mixture of air and gasoline and prepare it to be
sucked through the intake valves and into the cylinders during
Stroke 1, described above. Specs usually identify the carburetor
name and how many carburetors are used. Fuel injection comes
with different names such as Fuel Injection (FI), Digital Fuel
Injection (DFI), Electronic Sequential Port Fuel Injection (ESPFI),
Programmed Fuel Injection (PGM-FI), etc.
 Compression Ratio: Here's a definition from Motorcycles
Forum moderator, Bill Wood:
 "Think of Compression Ratio this way: When the piston is at the
bottom of the cylinder, say you could pour 100cc of water into
the sparkplug hole (both valves closed) and it would be full.
When the piston is at the top of its stroke, you can only pour
10cc of water into the hole to fill it. The compression ratio would
be 100 to 10 or 10 to 1. That's about as easy to understand as I
can make it. Oops, forgot to say -- Higher compression ratios (in
general) will let the engine make more power, require higher
octane gas and be harder for the starter to turn over."
 Maximum Torque: Torque is described as twisting force. This
is the maximum amount of twisting force the engine can put out
and at what value of engine Revolutions Per Minute (RPM). Put
simply, torque is the "grunt, stretch your arms, push your
eyeballs into their sockets" quality when you aggressively use
the throttle and accelerate hard. The higher the number, the
more forceful that feeling is.
 Maximum Horsepower: This is the maximum amount of
horsepower delivered by the engine. It occurs at a particular
engine speed. Horsepower (HP) and torque are interrelated with
RPM by the formula HP = TORQUE X RPM / 5252.

 Drivetrain:
 Transmission: The specs may show the transmission as 4-speed,
5-speed, 6-speed, or an automatic transmission such as found in
some bikes and most scooters.
 Final Drive: The final drive is what connects the engine and
transmission to the rear wheel. Options are a chain, belt, or
driveshaft.
 Brakes: There are many brake systems given in motorcycle
specs. The usual system is a disc front brake controlled by the
right handlebar brake lever and a rear disc or drum brake
controlled by the rightside foot brake pedal. There are also
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 Linked Braking Systems (LBS) where use of either the front
brake lever or the foot brake will activate both front and rear
brakes. A variation on LBS is the Integrated Braking System
(IBS) where the foot brake also controls a portion of the front
brake. In some integrated braking systems, the front brake will
also control a portion of the rear brake.
 Disc brakes are made of a rotor that is attached to the wheel
and a caliper that is fitted over the edge of the rotor. The caliper
contains one or more pistons under hydraulic pressure that,
when activated by a hand brake lever or foot brake pedal, will
push against the brake pads that then contact the rotor to
create friction that stops the bike. There are fixed rotors and
floating rotors. The floating rotors can move and expand and
contract thereby allowing less heat to be generated and braking
performance to be increased.
 Anti-Lock Braking Systems (ABS) may also be part of a
motorcycle braking system. ABS uses computer controls to keep
the brakes from locking by applying and releasing the brakes
very rapidly, always just short of a lockup.
 Front Suspension: Springs and shock absorbers are used in
various configurations to provide a comfortable ride. The
concepts used for both front and rear suspensions are similar
but the configurations of springs, dampers, and links are quite
different.
 Spring pre-load is the amount of compression already in the
spring before applying any load. Many systems allow you to
adjust the pre-load to suit the expected road conditions or rider
preferences.
 Most motorcycles use a telescopic front suspension consisting of
two fork tubes containing springs and some method to control
their motion. When brakes are applied, the front end tends to
dive because of weight transfer. When the bike hits a bump, the
spring also compresses to absorb the shock. To keep the spring
from bottoming, some form of compression damping is used. As
the spring comes back up, rebound damping is used to control
its travel. Without damping, the spring would propel the rider up
and down in pogo stick fashion. Many bikes have methods to
control and adjust compression damping and rebound damping
and these are spelled out in the motorcycle specs.
 Most telescopic front forks have a smaller top portion that is
pushed into a larger lower portion. A variation on this is
the inverted fork where the fork tubes are essentially turned
upside down with the upper portion sliding down outside the
lower portion.

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  Rear Suspension: Today, most bikes use a swingarm system
that is laterally fastened to the frame in front of the rear wheel
and moves up and down in an arc. Two arms extend back and
hold the rear wheel. One or two shock absorbers connect
between the frame and the swingarm to provide spring action
and appropriate damping. Some bikes use a single-sided
swingarm.
 Older bikes had no rear suspension and were known as hard
tails. Many bikes today have hidden rear springs and shocks to
give a hard tail look but a soft tail ride. The Harley-Davidson
Softail line is an example.
 Tires: The first two numbers in a tire size indicate the width of
the tire and the height of the sidewall. For example, 240/40
indicates that the tire width is 240mm across the tread and the
aspect ratio is 40. The aspect ratio, expressed in percent, when
multiplied by the width gives the height of the sidewall. Thus,
the example tire size tells us that the tire is 240 mm wide and
the sidewall is 96mm high (0.40 X 240).
 Various Dimensions:
 Seat Height: Seat height may be given as measured with a rider
aboard (laden) or it may be given unladen. Riders may be
interested in the seat height to tell them how easy it will be for
them to get their feet flat on the pavement when stopped. See
my Seat Heights article.
 Rake and Trail: Rake is the angle of the fork away from vertical
toward the rider. Trail is the distance on the ground between a
vertical line dropped straight down from the center of the wheel
and a projection of the fork extended until it touches the ground.
As the rake increases, the trail increases. The more rake, the
more stable the handling at speed. As rake decreases, handling
becomes easier at low speeds.
 Wheelbase: This is the number of inches measured from front
axle to rear axle.
 Weight: Weight may be given as wet weight with all lubricants,
liquids and gasoline added or it may be dry weight with nothing
added.
 Fuel Tank Capacity: Capacity is usually given including
reserve tank.

Specifications
Main Components

Overall length 2,041 mm (80.4 in)

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 Overall width 771 mm (30.4 in)
Overall height 1,071 mm (42.2 in)
Wheelbase 1,306 mm (51.4 in)
Minimum ground
clearance 165 mm (6.5 in)
Caster angle 26º 30´
Trail 100 mm (3.9 in)
Curb weight 129 kg (284 lb)
Maximum weight capacity *1 115 kg (254 lb)
Maximum luggage weight *2 Rear carrier 3.0 kg (6.6 lb)

Minimum turning radius 2.03 m (6.660 ft)

*1 Including rider, passenger, all luggage, and accessories.
*2 Includes the weight of the luggage and added acc

■ Service Data
Front 80/100-18M/C 47P
Tyre size Rear 90/90-18M/C 51P

Tyre type Bias-ply, tube

Recommended Front MBPSTAR MP-217
Tyres Rear MBPSTAR MP-218
Driver only
Front 175kpa,25psi
Rear 200kpa,39psi

Removing & Installing Body Components

Battery # Removal
Make sure the ignition switch is in the (off) position.
1. Remove the right side cover. 2 P. 48
Negative 2. Remove the fuse holder from the battery holder.
e
Maintenanc

terminal 3. Disconnect the negative - terminal from the battery.

Scre
Positive 4. Disconnect the positive + terminal from the battery.
Screw terminal 5. Remove the battery holder by removing the bolts.
w
6. Remove the battery taking care not to drop the terminal
nuts.

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Bolts
Battery holder Battery Fuse
holder
 u Pull out the battery and battery holder together
from motorcycle.

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Maintenance Fundamentals

Battery
Your motorcycle has a maintenance-free type battery.
You do not have to check the battery electrolyte level or
add distilled water. Clean the battery terminals if they
become dirty or corroded.
Do not remove the battery cap seals. There is

e
Maintenanc
no need to remove the cap when charging.

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 3WARNING NOTICE
Your battery is a maintenance-free type
Installing non-Honda parts may make and can be permanently damaged if the
your motorcycle unsafe and cause a cap strip is removed.
crash in which you can be seriously
hurt or killed. NOTICE
An improperly disposed of battery can be
Always use Honda Genuine Parts or harmful to the environment and human
equivalents that have been health.
designed and approved for your Always confirm local regulations for proper
motorcycle. battery disposal instruction.

Replacing Parts
Always use Honda Genuine Parts or their equivalents to ensure reliability and safety.

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 Maintenance Schedule

Pre- Frequency
*1 Annua Regula Refer to
Item ride
Check × 1,000 1 4 8 12 16 20 24 l r page
s
2 P. km Check Replac
32 × 1,000 0.6 2.5 5 7.5 10 12.5 15 e
mi
e
Maintenanc

Fuel Line I I I I I I I –
Fuel Level I –
Fuel Strainer Screen –
Throttle Operation I I I I I I I I 69
Choke Operation I I I I I I I –
Air Cleaner *2 R 42
Crankcase Breather *3 70
Spark Plug I R I R I R 49
Valve Clearance I I I I I I I –
Engine Oil I R R R R R R R R 51

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Engine Oil Strainer Screen –
Engine Oil Centrifugal filter –
Engine Idle Speed I I I I I I I I –
Secondary Air Supply System I I I –

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 Maintenance Level : Lubricate
: Intermediate. We recommend service
by your dealer, unless you have the
necessary tools and are mechanically
skilled. Procedures are provided in an
official Honda Shop Manual.
: Technical. In the interest of safety,
have your motorcycle
30 serviced by your dealer.
Maintenance Legend
I : Inspect (clean, adjust, lubricate, or
replace, if necessary)
: Replace R

: Clean

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 Removing & Installing Body Components u Headlight Case

Headlight Case # Removal

1. Remove the screws.
2. Remove the headlight case.
Screw 3. Disconnect the connector and pull out the
s Headlight case Screw position light socket.
e
Maintenanc

s Install the parts in the reverse order of

removal.

Connect
or

Position light
socket
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 3WARNING
For the recommended spark plug, see “Specifications.”

Checking Spark Plug

Use only the recommended type of spark plug

in the recommended heat range.
NOTICE
Using a spark plug with an improper heat range can cause engine
damage.

1. Disconnect the spark plug cap from the spark plug wrench. 2 P. 43
spark plug. 4. Inspect the electrodes and centre porcelain
2. Clean any dirt from around the spark plug for deposits, erosion or carbon fouling.
base. u If the erosion or deposit is heavy,
3. Remove the spark plug using provided replace the plug.
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u Clean a carbon or wet-fouled plug
with a plug cleaner, otherwise use a
wire brush.

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Checking the Engine Oil (Change oil)
Check brakes
See specifications manual for the continuation
 Self check 4.2.1

Multiple Choice:

Direction:
Choose the right answer among the given choices by writing
the letter of it in the space provided for.

1. Before performing electrical work, you should.

a. Disconnect the battery positive terminal.
b. Disconnect the battery Negative terminal.
c. Disconnect the battery both negative and positive terminal.
2. When disconnecting the terminal cable,
a. loosen the cable nut and raise the cable straight up
without twisting or prying it.
b. loosen the cable nut and raise the cable straight down
twisting or prying it.
c. loosen the cable nut and raise the cable pulling it up.
3. When securing terminals be sure to cover the.
a. Cover the negative
b. Cover the positive
c. Cover both terminals
4. If a pre-coated part is retightened,
a. loosened or caused to move in any way
b. it must be recoated with the specified adhesive.
c. Loosen both
5. During disassembly,
a. keep parts in the appropriate order to facilitate
reassembly.
b. keep parts separately to facilitate
reassembly.
c. keep parts all together facilitate
reassemble

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 Answer key 4.2.1

1. A
2. A
3. B
4. B
5. A

LEARNING OUTCOME # 3 Apply information in manual

CONTENTS:
1. Interpret manual

ASSESSMENT CRITERIA:
The learning outcome stated above is attained if you can demonstrate the following:

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1. Manual is interpreted according to job requirements
2. Work steps are correctly identified in accordance with manufacturer specification
3. Manual data are applied according to the given task
4. All correct sequencing and adjustments are interpreted in accordance with
information contained on the manual or specifications
CONDITIONS: Students /trainees must be provided with the following:

3. Supplies/materials
- manufacturing specifications
- repair manual
- maintenance manual
- periodic maintenance manual
4. Instructional materials
- reference books
- professional emergency
- learning guides
- modules,
CDs, VHS tapes, transparencies
METHODOLOGY:
7. Lecture/demonstration
8. Dualized
9. Distance learning
ASSESSMENT METHODS: Written /oral examinations
6. Direct observation
7. Project method
8. Interview
Information Sheet 4.3.1
Applied Information in Manuals.
Objectives/s:

At the end of the lesson, you should be able to:

1. Applied Information in Manuals.

What is the purpose of manual?

Lesson Summary. An office manual is a resource for employees that

provides a framework about a company and individual responsibilities. The
office manuals purpose is to save time, create standard guidelines for
everyone, and provide a solid foundation of knowledge

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Maintenance Manual means the technical document that describes the
asset, how it operates, contains instructions, the preventive action
program, suggestions for corrective action, lists of spare parts, correction of
faults, danger warnings and the assets catalogue, among others

What is periodic maintenance?

periodic maintenance. Significant activities carried out regularly

(according to predetermined schedule) to maintain the condition or
operational status of a building, equipment, machine, plant, or system. Also
called time based maintenance.

Self Check 4.3.1

Answer the following:

1. What is the purpose of manual?

2. What is a periodic maintenance manual?

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 Answer key 4.3.1

1. An office manual is a resource for employees that provides a framework

about a
company and individual responsibilities.
a. The office manuals purpose is to save time, create standard guidelines
for
everyone, and provide a solid foundation of knowledge
2. periodic maintenance. Significant activities carried out regularly
(according to

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 predetermined schedule) to maintain the condition or operational status
of a building,
equipment, machine, plant, or system. Also called time
based maintenance

LEARNING EXPERIENCE

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LEARNING OUTCOME # 4 Store manuals
CONTENTS:
1. Store manual

ASSESSMENT CRITERIA:
The learning outcome stated above is attained if you can demonstrate
the following:
1. Manual or specification are stored appropriately to ensure prevention
of damage, ready access and updating of information when required
in accordance with company requirements.

CONDITIONS: Students /trainees must be provided with the following:

1. Supplies/materials
- manufacturing specifications
- repair manual
- maintenance manual
- periodic maintenance manual
2. Instructional materials
- reference books
- professional emergency
- learning guides
- modules,
CDs, VHS tapes, transparencies
METHODOLOGY:
1. Lecture/demonstration
2. Dualized
3. Distance learning
ASSESSMENT METHODS: Written /oral examinations
1. Direct observation
2. Project method
3. Interview

Information Sheet 4.1.1

Store manual

Steps in storing manuals.

After using the manual/s

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 a. Wipe it with clean cloth and unfold all pages if necessary.
b. Put it in sealable pouch.
c. Place it into box to save it from outside radical force.
d. Keep the box away from any possible source of fire or the like.
e. Situate in an accessible location where it easy to reach and
see.

Self check 4.1.1

What are the steps in storing manuals.

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 Answer key 4.1.1

Steps in storing manuals.

a. Wipe it with clean cloth and unfold all pages if necessary.
b. Put it in sealable pouch.
c. Place it into box to save it from outside radical force.
d. Keep the box away from any possible source of fire or the like.
e. Situate in an accessible location where it easy to reach and see.

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EVIDENCE PLAN

Competency
Motorcycle/Small Engine Servicing NCII
Standard

Unit of Competency Read, Interpret and Apply Specification and Manual

Ways in which evidence will be collected:

Demonstr
Question/
Interview
(tick the column

ation
The evidence must show that the candidate…

 *Identify and access appropriate

manuals as per job requirement
 Check version and date of manual to
ensure correct specification and
procedures are identified
 Locate relevant sections, chapters of
manuals/specification in relation to the
work to be conducted
 *Interpret information and procedure
from the manual in accordance to the
industry practices
 *Interpret manual according to the job
requirement
 Correctly identify work steps in
accordance with the manufacturer
specification
 *Apply manual data according to the
given task
 Interpret all correct sequencing and
adjustment in accordance with the
information contained on the manual or
specification
 *Store manual appropriately to ensure
prevention of damage, ready to access and
updating of information when required in
accordance with the company requirement
Note: * Critical aspect of competency

Learner’s signature Date:

Facilitator’s
Date:
Signature

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Observation Checklist

Qualification Level Motorcycle/Small Engine Servicing NC II

Learner’s Name:

Facilitator’s Name:

Assessment Center:

Unit of Competency: Read, Interpret and Apply Specification and Manual

Competency Standard: Motorcycle/Small Engine Servicing NC II

Date of Assessment:

Time of Assessment:

Instruction for Demonstration:

Materials and Equipment:

Manuals/ catalogues relative to Automotive, job order, requisition, actual
vehicle

Observation: To show if
evidence is
During the demonstration of skills did the candidate:
demonstrated

YES No N/A
 *Identified and accessed appropriate manuals as per
job requirement
 Checked version and date of manual to ensure correct
specification and procedures are identified
 Locate relevant sections, chapters of
manuals/specification in relation to the work to be
conducted
 *Interpreted information and procedure from the
manual in accordance to the industry practices
 *Interpreted manual according to the job requirement

 Correctly identified work steps in accordance with the

manufacturer specification
 *Applied manual data according to the given task

 Interpreted all correct sequencing and adjustment in

accordance with the information contained on the
manual or specification

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 *Stored manual appropriately to ensure prevention of
damage, ready to access and updating of information
when required in accordance with the company
requirement
The candidate’s demonstration was:

Satisfactory Unsatisfactory

Questioning / Interview

Learner’s Name:

Assessment Center:

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Unit of Competency: Read, Interpret and Apply Specification and
Manual

Competency Standard: Motorcycle/Small Engine Servicing NC II

Satisfactory
response
Questions:

The candidate should answer the following question: YES NO

1. How important is storing manual/s?

2. What are the information can we get at the VIN?

3. What is maintenance schedule?

4. What are the different types of Manuals?

5. What is a service manual?

6. What is an owner’s manual?

The candidate underpinning knowledge was:

Satisfactory  Not satisfactory 

Feedback to candidate:

The candidate’s overall performance was:

Satisfactory  Not satisfactory 

PERFORMANCE TEST

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Learner’s Name: Date:

Unit of Competency: Test Attempt

Read, Interpret and Apply Specification and 1 st
2nd 3rd
Manual

Direction: Overall Evaluation

Level Performance Levels

Call instructor, ask Achieved
your instructor to
assess your 4- Can perform this skills without
supervision and with iniative and
performance in the
adaptability to problem situation
following critical
task and 3- Can perform this skills satisfactorily
without assistance or supervision
performance
criteria below. 2- Can perform this skills satisfactorily
but requires some assistance or
You will be rated supervision
based on overall 1-can perform parts of this skill
evaluation on the satisfactorily but requires considerable
right side. manual according to the job requirement
*Interpret assistance and supervision

 Correctly identify work Instructor will initial

steps in accordance level achieved
with the
manufacturer specification
 *Apply manual Performance Standards
data according to the given task
For acceptable achievements, all items should YES NO N/A
 Interpret all correct
receive sequencing
a “YES” and adjustment
or “N/A” responsein
accordance with the information contained on the
*Identify
 manual and access appropriate manuals as
or specification
per job
 *Store requirement
manual appropriately to ensure prevention of
Check version
 damage, and date
ready to access of manual
and updating to ensure
of information
correct
 when required in accordance with the companyare
specification and procedures
identified
requirement
 Locate relevant sections, chapters of
manuals/specification in relation to the work
to be conducted
 *Interpret information and procedure from
the manual in accordance to the industry
practices

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 GLOSSARY OF TERMS

Assessment the process of gathering and judging evidence in order to

decide whether a person has achieved a standard of
competency or competence objective.
Automatic transmission a transmission in which gear ratios are
changed automatically instead of by hand or in a manual
transmission.
Continously Variable Transmission is an automatic transmission that
can change seamlessly through a continuous range of gear ratios
Brake an energy conversion device used to slow, stop or hold a
vehicle or mechanism.
Clutch a coupling that connect and disconnect a shaft from its drive
while the drive mechanism is running.
Coolant the liquid mixture of about 50 percent antifreeze and 50
percent water used to carry heat out of the engine.
Drive Line an assembly of one or more driveshafts, universal joints
that forms the driving connections.
Engine a machine that converts heat energy into mechanical energy.
Fuel any combustible substance.
Fuse a device that opens an electric current when excessive current
flows, to protect equipment in the circuit
Learning module a segment of a given body of skill for which a
measurable learning objective can be identified. The term is
also used to describe a self-contained booklet covering a
specific item of skill or knowledge. (Vocational Training:
Glossary of Selected Terms, ILO)
Overdrive transmission gearing that causes the output shaft to
overdrive or turn faster than input shaft.
Speedometer a device on display in the instrument panel that shows
the driver how fast the vehicle is moving.

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Trainer a person who directs the practices of skills towards immediate
improvement in some task.
Training a systematic process of the development of competencies
required by an individual to perform adequately in a given job
or task.
technical training program for the purpose of acquiring and developing
job-related skills (RA 7796 – TESD Act of 1994)
Trainers/trainors - persons who provide training, to trainees aimed at
developing the latter’s capacities for imparting attitude,
knowledge, skills and behavior patterns required for specific
jobs, tasks, occupations or group of related occupations (RA
7796 – TESD Act of 1994)
- persons who direct the practice of skills towards immediate
improvement in some task (RA 7796 – TESD Act of 1994)
Training a process of the development of skills, related knowledge,
attitudes and behavior patterns required for the adequate
performance of a given task or job.
Training center an establishment specialized in training people for
skilled occupations, usually comprised of classrooms and training
workshops. Training centers generally exist outside the formal education
system and can be either privately or government funded. (Vocational
Training: Glossary of Selected Terms, ILO

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 Institutional Assessment

1. Which of the following information is not included in a service

manual?
a. specification
b. sales and promotion
c. disassembly procedures
d. detailed theoretical information
e. vehicle colors and styling

2. Which of the following information is usually shown as

measurement,
clearances and numbers?
a. Procedure Information
b. Troubleshooting information
c. specification information
d. overhaul procedures
e. special tool

3. Specification that include spark plug gap, ignition timing and

carburetor adjustment are called?
a. Tune-up specification
b. Capacity specification
c. Overhaul and maintenance specification
d. Procedure specification
e. None of the above

4. Specification that show bearing clearance, and ring gaps are

called?
a. Tune-up specification
b. General engine specification
c. Capacity specification
d. Overhaul and maintenance specification
e. Troubleshooting specification

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 5. Torque specification are identified as:
a. Torque on nuts and bolts
b. Engine torque at certain speeds
c. Torque applied to the crankshaft during
operation
d. Torque applied to the generator
e. Torque applied on turns

6. Technician A says that plug gaps, clearances and torque on bolts

cannot be found in a service manual. Technician B says overhaul
procedures in the sales literature. Who is right?
a. A only
b. B only
c. Both A and B
d. Neither A or B
7. Technician A says that diagnosis information can be found in the
service manuals. Technician B says that diagnosis information can
be found only in literature obtained from the manufacturer. Who
is right?
a. A only
b. B only
c. Both A and B
d. Neither A or B
8. Technician A says that the VIN does not include any information
about the engine in the vehicle. Technician B says that the VIN
does not include the vehicle serial number. Who is right?
a. A only
b. B only
c. Both A and B
d. Neither A or B

9. When looking for the VIN on the vehicle, technician A says it can
be found on the dashboard on the driver’s side. Technician B
says it can be found in the owner’s manual. Who is right?
a. A only
b. B only
c. Both A and B
d. Neither A or

10. Before performing electrical work, you should.

a. Disconnect the battery positive terminal.

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 b. Disconnect the battery Negative terminal.
c. Disconnect the battery both negative and positive terminal.
11. When disconnecting the terminal cable,
a. loosen the cable nut and raise the cable straight up
without twisting or prying it.
b. loosen the cable nut and raise the cable straight down
twisting or prying it.
c. loosen the cable nut and raise the cable pulling it up.
12. When securing terminals be sure to cover the.
a. Cover the negative
b. Cover the positive
c. Cover both terminals
13. If a pre-coated part is retightened,
a. loosened or caused to move in any way
b. it must be recoated with the specified adhesive.
c. Loosen both
14. During disassembly,
a. keep parts in the appropriate order to facilitate
reassembly.
b. keep parts separately to facilitate
reassembly.
c. keep parts all together facilitate
reassemble

ANSWER KEY 4.1-1

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 1. B
2. C
3. A
4. D
5. A
6. D
7. A
8. D
9. A
10. A
11. A
12. B
13. B
14. A

score

Name ______________________________________ Date _______________________

A B C D E F A B C D E F
1. 13.

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2. 14.

3. 15.

4. 16.

5. 17.

6. 18.

7. 19.

8. 20.

9. 21.

10. 22.

11. 23.

12. 24.

score

Name ______________________________________ Date _______________________

A B C D E F A B C D E F
1. 13.

2. 14.

3. 15.

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4. 16.

5. 17.

6. 18.

7. 19.

8. 20.

9. 21.

10. 22.

11. 23.

12. 24.

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https://dirtbikemagazine.com/2020-off-road-bike-buyers-guide/

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