MOTORCYCLE screwdriver tips: Repair your motorcycle yourself

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MOTORCYCLE screwdriver tips: Repair your motorcycle yourself
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MOTORCYCLE screwdriver tips: Repair your motorcycle yourself

Big overview: repair everything to do with motorcycles
MOTORCYCLE screwdriver tips

In this special you will find practical workshop articles on everything to do with motorcycles. Divided into the most important categories, MOTORRAD provides important screwdriver tips and instructions for self-help.

03/18/2011

Workshop special

The way to a real do-it-yourself screwdriver: You start out as a simple screwdriver and grow with your tasks. But be careful: there are many traps lurking. But if you take all the tips and tricks into account and have the right (screw) wrench ready, you will not grope into it.

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Don’t forget: first clean, then screw! During certain work, dirt can get into sensitive areas such as fine threads. Place the motorcycle on a level surface. Be aware that oil or other liquids can suddenly leak. So put old blankets, newspapers or cardboard boxes under them to protect the floor. And have enough cleaning rags ready.


MOTORCYCLE screwdriver tips: Repair your motorcycle yourself


Bilski

Help for screwdrivers and those who want to become one.

Protect yourself against aggressive liquids such as brake cleaners or acids, for example with gloves and protective goggles. Bright light is important, especially when working in a garage or workshop room. Extra tip: A headlamp or a mobile spotlight are ideal for working in hidden places.

Before starting work, lay out all the tools. Please refer to the respective level to find out which parts you need. Caution! Do not use an absolutely cheap tool from a discounter.

It is also essential to obtain beforehand: a repair and maintenance manual for the motorcycle in question. This provides circuit diagrams and detailed information on filling quantities, dimensions as well as exploded and sectional drawings as well as other schemes that ensure a better understanding of the respective work steps. 

Original workshop manuals are ideal, although they are not officially sold but are usually only offered for sale as second-hand goods, for example on Ebay or in the classifieds section. Tip: Before starting the actual screwdriving work, always first get an overview and go through all work steps once “dry”. You may need a friend to help you with certain tasks.

If not all tasks can be done safely and without outbursts of anger or wrenches flying around, it is better to keep your hands off work from the next higher level. Remember that if you have to take a longer break from screwing, a half-screwed, immobile machine will not stand in the way or in the rain.

Below you will find instructions on various tasks that need to be carried out on the motorcycle. You will receive a list of tools, dangers involved in repairs and valuable tips. So that you know which task you can safely approach, there are three levels of difficulty.  

MOTORCYCLE screwdriver tips: Repair your motorcycle yourself

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Level 1: handlebars and fittings, engine lubrication and battery …

You feel like the absolute beginner – and you are, because apart from a simple bookshelf you have not done anything yet. But knowing that no master has fallen from the sky, you have all the utensils ready. Happy to work, dear beginner!

Handlebars, levers and fittings

The task: Adapt to personal ergonomics
Tool: Ring / open-end wrench 8–14, hexagon socket 3–6, ¼-inch ratchet with extension and sockets 8–14, cross-head bits and – if necessary – Torx bits
Targeted working time: 20 minutes
Watch out, trap: Do not overtighten the screws, because cast fittings break and tear comparatively quickly. If the handlebars are misaligned: check the freedom of movement and, when the steering wheel is fully turned, check the functions of the cables and fittings.
Top tip: Only tighten the lever clamps so tight that they can just be twisted by hand – this means that these fittings are less prone to breakage if they fall over.

Fuses

The task: To deceive
Tool: Needle nose pliers; if the cladding has to be removed: see recommended tools there.
Targeted working hours: 10 mins
Watch out, trap: Ignition off, otherwise there is a risk of short circuits!
Use only replacement fuses with exactly the right value. A fuse that is too weak will blow again immediately; an excessively strong fuse can cause consequential damage such as a cable fire.
Top tip: If possible, check the built-in fuses again, obtain a test lamp for this

 

Chain KIT

The task: Check and adjust chain slack
Tool: Ring / open-end wrenches 8–12, ring / open-end wrenches 17–36
Targeted working time: 10 minutes
Watch out, trap: A chain that is tensioned too tightly can, among other things, lead to bearing damage at the gearbox output. Note the recommended chain sag according to the manufacturer (at least two centimeters, significantly more for enduro bikes; see manual)
Top tips: Check the chain tension at various points in the compressed state (ideally with a helper sitting on the motorcycle during the adjustment). So that the wheel sits correctly in the swing arm and is straight on the track, it is essential to pay attention to the markings between the screw connection and the swing arm on both sides. To be on the safe side, measure the distance between the swing arm end and the axle bolt on each side. The dimensions should match.

 
Disguise

The task: Change smaller fairing parts, side covers or cockpit windshield
Tool: Ring / open-end wrench 8–14, ¼-inch ratchet with extension and sockets 8–14, Phillips bits, hexagon socket 4–6
Targeted working time: 10 minutes
Watch out, trap: Not by force! The plastic parts break and tear quickly under tension.
Top tip: Put screws, rubber rings and other small parts in groups in the provided boxes or boxes, then everything is ready for the final assembly
close at hand and nothing is lost. 

Engine lubrication

The task: Change oil and filter
Tool: Ring / open-end wrench 8-24; for oil filter housing: ¼ inch ratchet with extension and sockets 8–12. Also get: oil filter tape and used oil pan
Targeted working time: 30 minutes
Watch out, trap: The drain plug is usually located in the aluminum motor housing, it must not be tightened too tight under any circumstances. The fine thread breaks comparatively quickly.
Top tips: Run the engine warm (not hot), cold oil is too thick to drain completely. As a precaution, change the sealing ring at the same time. Keep the receipt of the new oil in order to recycle the used oil.
Tip for on the go: improvise a funnel from coated cardboard packaging.

 

lighting

The task: Change light bulbs
Tool: Hexagon socket 3–6, ¼-inch ratchet with extension and sockets 8–14, Phillips bits.
Targeted working hours: 10 mins
Watch out, trap: Do not touch the glass with your bare hands; Dirt, grease and sweat attack the sensitive coating. Better just touch the metal ring.
Top tip: Even if the advertising promises better radiation values: only use light bulbs approved for the model, as this could possibly result in a wrong radiation pattern.

 
battery

The task: Removal and installation (only recommended for beginners if easily accessible, e.g. under the bench)
Tool: 1/4 inch ratchet with extension and 10-14 sockets, Phillips head
Targeted working time: 15 minutes
Watch out, trap: Don’t forget to switch off the ignition, otherwise there is a risk of short circuit!
Top tips: When removing, always unscrew the minus pole first, when installing, connect the plus pole first. Screws on the poles should not be overtightened. If possible, smear the poles with grease.

 
Extra work

Check screws, adjust light, change cardan oil, replace fuel tap and filter, adjust and replace mirrors, retrofit complete seat, mount fenders and rear wheel covers from the range of accessories, check and replace air filters (if easily accessible).

Level 2: brakes, wheels, chassis …

You will not be afraid of multi-page assembly instructions. Her motto: Do ​​it yourself! You also want to get to know your motorcycle better while screwing. Solve the following moderately difficult problems and prove that you are a good playmate.

Luggage system

The task: Assemble
Tool: ½ inch ratchet with extension and sockets 8–14, ring / open-end wrench 8–14, hexagon socket 3–8, plastic hammer, file.
Targeted working hours: 1 hour
Watch out, trap: See assembly instructions before buying: Need about the
Indicators are relocated? Functional check with suitcases and bags before the first journey: Does the swing arm hit when it is compressed? Are the indicators and lights clearly visible? Is the distance to the exhaust (fire hazard) sufficient??
Top tips: First of all, just apply all screws and then tighten the opposing screws firmly. Check the support system for tension in between. File off any sharp burrs.

Electrical accessories

The task: Installation of intercom, navigation device or other.
Tools: screwdriver (cross, slotted, possibly Torx), side cutter, ring / open-end wrench 8–14, hexagon socket 3–6, ¼ inch ratchet with extension and sockets 8–14, multi-meter.
Targeted working hours: 1 hour 15 minutes
Watch out, trap: Is the usefulness checked in advance, for example through test or experience reports from trusted persons or institutions? Some additional devices of dubious origin work so badly that it is a shame to do the screwing work. Bad sign: assembly instructions only in a foreign language and confusing.
Top tips: Do not connect directly to the battery, but to the ignition current. When assembling, sit on the motorcycle and make sure that diodes, indicators and LCD displays are in the field of vision.

Handles / heated grips

The task: Switch; for heated grips: assemble and connect.
Tool: Screwdriver with a long, thin shaft (for loosening old but still usable handles), Phillips screwdriver, hexagon socket 4–8, ring / open-end wrench 6–14, cutter (for easier cutting down of old handles), side cutters, multi-meter.
Targeted working hours: 1 hour 15 minutes
Watch out, trap: In the case of heated grips, be sure to check the assembly instructions: They are larger
Modifications to the wiring harness required?
Top tips: Even if the instructions allow it: Do not connect heated grips directly to the battery, only to the ignition. Otherwise there is a constant risk that the battery will discharge. Fit new handles with soapy water.

Brakes

The task: Change pads
Tool: ½ inch ratchet with extension and sockets 10–14, ring / open-end wrench 8–14, hexagon socket 6–8, large slotted screwdriver or flat chisel, pin punch, hammer.
Targeted working hours: 30 minutes
Watch out, trap: Don’t forget the lock washers! Check the brake fluid level with new pads: it must never be above the maximum mark. Before driving for the first time, pull the brake lever until brake pressure is built up, otherwise there is an increased risk of an accident.
Top tips: Before pushing back, clean the brake piston with brake cleaner, old pads
use to push back the pistons.

bikes

The task: Install and remove
Tool: ½ inch ratchet with extension and sockets 24–36, ring / open-end wrench 24–36, plastic hammer.
Targeted working hours: 20 minutes
Watch out, trap: Swap or forget about spacer sleeves when reinstalling. This limits the roadworthiness and can lead to expensive consequential damage.
Top tips: Jack up the motorcycle beforehand (e.g. on an empty drinks crate or main stand with wooden plates underneath) or hang it up so that the wheels can run freely. Carefully secure the machine against falling over and rolling away (for example, fix the brake lever with a rubber band). Lightly grease axles before installation.

Redirection

The task: Exchange
Tool: Allen key 6–10, ½ inch ratchet with extension and sockets 10–19, ring / open-end wrench 10–19, hammer, pin punch.
Targeted working hours: 30 minutes (without disguise)
Watch out, trap: Relieve the suspension (e.g. using tension belts), otherwise there is a risk of injury from sudden collapse when the bolts are dismantled. Only use suitable parts with an operating permit, as otherwise road safety is endangered
Top tips: Jack up or hang up the motorcycle securely (see wheel removal). In the case of retrofit products, it is essential to compare the dimensions permitted beforehand. When redirecting, it may be necessary to use spacers and precision bearings to reduce play. If in doubt, it is better to consult an expert.

Exhaust system

The task: Exchange, possibly replace with retrofit parts.
Tool: Ring / open-end wrenches 8–14, ¼-inch and ½-inch ratchets with extension and sockets 8–12 (¼-inch) and 10–14 (½-inch), hexagon socket 4–6, combination pliers.
Targeted working time: 30 minutes (without disguise).
Watch out, trap: Old seals should no longer be used, so get new ones before screwing. Tighten the manifold bolts carefully – cracks in the aluminum engine housing caused by over-tightening can be expensive!
Top tips: Initially only apply the system loosely to all screw connections, then tighten the screws step by step to prevent tension. This is particularly important for retrofit systems that are often not so precisely tailored. Lubricate the elbow thread thinly with copper paste.

Extra work

Mount the retrofit handlebar and foot edge system, replace the spark plugs, change the fuel line, change the ignition coil, swap the thermostat and blower motor, adjust the cables, mount the main stand, upholster the seat with a retrofit foam core and cover, adjust the valve clearance on a simple engine (e.g. two-valve boxer).

Level 3: electrics, clutch, bearings and more …

Your machine is your favorite toy and there is always something to do. If not, are you really looking for a job? Don’t worry, you won’t get bored with the following work. On the screws, set, go!

Electrics

The task: Troubleshooting, cable replacement
Tool: Multi-meter, wire cutter, screwdriver, wire stripper.
Targeted working time: 3 hours
Watch out, trap: When unplugging connections on certain motorcycles, an error code is stored in the control unit, which can usually only be neutralized by a specialist workshop. In the event of incorrect connections (without clear plug connections) there is a risk of short circuits.
Top tips: When laying new cables, watch out for chafing points and avoid them. Mark cables of the same color without confusing them, for example with colored adhesive strips

Chain KIT

The task: Switch
Tool: ½ inch ratchet with extension and sockets 19–32 (buy larger sockets depending on the model), hexagon socket 5–6, riveting tool, torque wrench (ideal: Flex).
Targeted working time: 1 hour 30 minutes
Watch out, trap: There may be extremely large leverage forces when removing the front pinion
required, and an impact wrench is recommended. Do not forget the pinion safety device (if present) during installation, otherwise serious consequential damage can occur!
Top tips: Chain clip lock with closed side in the direction of travel. For perfect chain alignment: get a laser measuring device (available from 50 euros).

coupling

The task: Remove, check and replace.
Tool: Ring / open-end wrench 10–14, hexagon socket 4–6, ¼-inch ratchet with extension and sockets 8–12, torque wrench.
Targeted working time: 45 minutes
Watch out, trap: When unscrewing the clutch basket, parts can suddenly jump out due to pretension. Friction discs that are installed in the wrong order and insufficient clutch cable play cause considerable shifting problems and can lead to damage.
Top tips: Put the motorcycle on the side stand, then less oil will leak out. Use new seals if possible. Check the tightening torques with a torque wrench.

Steering head bearings

The task: To adjust
Tool: ½ inch ratchet with extension and sockets 12–27, hexagon socket 6–8, ring / open-end wrench 10–14, hook wrench.
Targeted working time: 1 hour
Watch out, trap: A steering head bearing that is too loose or too tight wears out extremely quickly and has a negative effect on driving safety. The bearing play must therefore be set very carefully.
Top tip: First tighten the bearing so that there is no play, then carefully approach it in extremely small steps until it moves smoothly.

Engine valves

The task: Adjust valve clearance
Tool: ¼ ”and ½” ratchets with extensions and nuts 8–12 (¼ ”) and 10–14 (½”), ring / open-end wrench 8–14, hexagon socket 4–6, blade gauge, torque wrench.
Targeted working time: 4 hours
Watch out, trap: Risk of confusion with shims below! It is best to record all valve clearance and corresponding shim dimensions precisely in the table. Be careful with incorrectly installed chain tensioners – major engine damage during operation cannot be ruled out!
Top tips: In the case of rocker arms, measure the valve clearance again after tightening the lock nut, as this process may change the clearance outside of the desired setting range. Use new seals.

Braking system

The task: Bleed the brakes and change the fluid.
Tool: Open-ended spanners 8–12, collecting container (empty canning jar), plastic hose with a suitable diameter, ideal: ventilation device (see picture, available from 25 euros).
Targeted working time: 30 minutes
Watch out, trap: Excessive brake fluid can lead to dangerous malfunctions while driving, therefore never exceed the maximum marking on the brake fitting! Only use the brake fluid recommended in the manual and do not mix it with others. Tighten sensitive brake line connections (banjo bolts) carefully with a torque wrench so as not to damage them.
Top tip: If possible, only change the fluid with freshly changed brake pads, because the fill level may no longer be correct when the pads are replaced later.

fork

The task: Maintenance, oil change and spring replacement.
Tool: ½ inch ratchet with extension and sockets 10–32, hexagon socket 6–10, hammer, plastic hammer, torque wrench, steel ruler.
Targeted working hours: 1 hour 30 minutes
Watch out, trap: Fork springs are often under strong pretension. When unscrewing
the aluminum fork plug quickly ruins the delicate fine thread. There are also many small parts that can easily be lost during disassembly. The oil level of replacement springs may differ from the recommendation for original springs. If you are unsure, it is better to consult experts and not fill in too much oil.
Top tips: Use tension belts to relieve the suspension. Prepare the organization principle and collection container for small parts.

Extra work

Change the throttle kit, change the oil pump, replace the fuel pump, change the starter, replace the cylinder head gasket, replace the alternator, mount the accessory half-shell cover, synchronize the carburetor (with synchrometer), mount the braided steel brake lines.

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