PWRS 1500 Power Sports Maintenance & Tune-Up

This course focuses on motorcycle, ATV, and snow machine maintenance and tune- up procedures. The course covers maintenance procedures such as oil and filter changing, valve adjustment, carburetor synchronization, and timing adjustment for power sports vehicles. Emphasis will be placed on tuning the entire vehicle to achieve maximum performance. The course will include instruction in special tool use, interpretation of factory manuals, manipulation of parts and pieces on vehicles, proper shop documentation of repairs, and safety precautions. The student will be required to provide a project power sports vehicle, hand tools, and personal safety equipment (1 lect., 2 lab)

Credits

3 credits

Major Topics

  • Oil filter and oil change procedures
  • Valve adjustments on 4 cycle engines
  • Cam chain adjustments
  • Spark plug changing, reading and selection concerns
  • Clutch adjustment and high altitude tuning
  • Brake adjustment
  • Drive chain adjustment and lubrication
  • Carburetor adjustments
  • High altitude carburetor jetting concerns
  • Air cleaner service
  • Battery service
  • Drive line and final drive service
  • Cable and control servicing
  • Suspension servicing and set up
  • Ignition verification and timing
  • Long term storage concerns
  • Proper work order documentation
  • An understanding of the powersports business.

Outcomes

In order to successfully complete this course, the student will:

1. Describe the safety concerns found in a typical powersports shop.

2. Describe the purpose of a work order.

3. Correctly fill out a work order.

4. Note authorization for additional work on a work order.

5. Recognize and be able to identify good customer service.

6. Estimate the cost of a tune-up.

7. Describe the true nature of what is being sold in a powersports store.

8. Describe some of the laws related to the handling of waste oil and other hazardous waste generated by a powersports store.

9. Differentiate between a factory service manual, a factory owner’s manual, and an aftermarket repair manual.

10. Use a factory service manual to look up specifications and other important data.

11. Use feeler gauges to measure valve lash.

12. Use calipers to take measurements accurate to .002".

13. Use a micrometer.

14. Use a dial indicator.

15. Use a ruler and a tape measurer.

16. Use a plug gaping tool.

17. Use an antifreeze tester.

18. Use timing light.

19. Use a degree wheel.

20. Use a mechanical tachometer.

21. Use a torque wrench.

22. Remove and replace a carburetor or a bank of carburetors from a powersports vehicle.

23. Disassemble, clean, and reassemble a simple powersports carburetor.

24. Recognize damaged fuel system components.

25. Replace old or damaged fuel system components and restore the serviceability of a fuel system.

26. Locate and service the fuel filters found on typical powersports vehicles.

27. Describe the standard method used to repair a rusty fuel tank.

28. Describe the method used to protect a fuel system from damage during long term storage.

29. Describe the effect altitude has on jetting in a fixed jet carburetor.

30. Use jetting charts to determine the factory recommended jetting for high altitude.

31. Describe the 4 major systems found in most typical carburetors.

32. Describe the method used to determine the system causing problems when a carbureted vehicle experiences fuel related performance problems.

33. Synchronize a multi-carburetor fuel system using a number of synchronization methods.

34. Set the idle on a carburetor fuel system.

35. Verify the operation of the throttle assurance device and/or system.

36. Service the air filter system found on typical powersports vehicles.

37. Describe the relationship between electricity and magnetism.

38. Describe how spark is produced in a coil.

39. Differentiate between the primary and secondary parts of the ignition system.

40. Describe a number of ignition systems found on powersports vehicles.

41. Describe the necessity for ignition timing, ignition advance, and ignition retard in a powersports vehicle.

42. Apply the tools needed to determine the timing on a powersports vehicle.

43. Determine if the timing is adjustable on a powersports vehicle.

44. Use the tools and techniques necessary to time a powersports vehicle.

45. Change spark plugs.

46. Describe the differences between a hot and a cold spark plug.

47. Read and interpret spark plugs as they relate to powersports vehicles.

48. Identify the components of the ignition system and describe their function.

49. Use the service literature available to find the correct timing specifications and parts applications for powersports ignition systems.

50. Use the service manual to look up the valve clearance specifications.

51. Use the appropriate measuring device to determine the valve clearances.

52. Set valve clearance on a number of different valve adjustment systems.

53. Adjust the cam chain on a powersports vehicle.

54. Use a compression tester to determine the soundness of a powersports engine.

55. Use a dial indicator and a degree wheel to determine crankshaft index on a pressed together powersports crankshaft.

56. Change the oil and filter in a powersports engine.

57. Determine the suitability of different brands of oil for powersports vehicle engines.

58. Describe the typical oil change interval on powersports vehicles.

59. Service the oil injection system found on 2-cycle powersports engines.

60. Describe the danger of mixing 2-cycle oils.

61. Describe the proper method for long term storage of a powersports vehicle engine.

62. Describe the function of a belt drive clutch system found on typical powersports vehicles.

63. Inspect and determine the serviceability of a drive belt.

64 Change a drive belt.

65. Use the service manuals to lookup high altitude clutching specifications.

66. Change weights, springs, and secondary clutch settings to maximize vehicle performance.

67. Inspect and determine serviceability of a chain and sprocket drive system.

68. Change oil in a final drive unit.

69. Inspect, lubricate and adjust control cables.

70. Adjust plate type clutches.

71. Change fluid in hydraulic clutch and brake systems using special techniques to prevent brake fluid spills on painted surfaces.

72. Adjust mechanical brakes.

73. Adjust shock absorbers.

74. Recognize oil leaks in suspension units.

75. Determine looseness in suspension assemblies.

76. Grease a powersports vehicle’s suspension.

77. Remove and replace a battery from a powersports vehicle.

78. Service a battery.

79. Inspect the bulbs and lamps found on a powersports vehicle.

80. Describe the danger of touching a halogen bulb.

81. Identify the circuit overload protection device.

82. Check to assure the presence of extra fuses in the fuse holder.

Other Information

Any information placed here must be adhered to by all instructors:

Required software: None Recommended text book: Contact instructor for current recommended text. Students are required to furnish the following auto safety equipment and basic hand tools: Provide safety glasses and protective coveralls Provide their own basic tools which include the following: flat and Phillips screwdrivers, pliers, standard and metric sockets, and sockets drivers and extensions, standard and metric wrenches , punches, hammers, gasket scraper, and other basic tools as needed CWC will supply the lifts and special tools.