When repairing motorcycles, general tools and special tools are often needed.

(1) General tools

The general tools required for motorcycle maintenance mainly include wrenches, screwdrivers, hand hammers, hand pliers, steel rulers, calipers, squares, thickness gauges, Dial gauge, dial indicator, etc.

① Wrench. The wrenches commonly used by motorcycle repairmen mainly include: open-end wrenches, torx wrenches, adjustable wrenches, socket wrenches, torque wrenches, hexagonal wrenches, etc., as shown in Figure 1-52.

Figure 1-52 Wrench

The open-end wrench is the most common type of wrench, also known as a dead wrench. The central plane of the opening forms an angle of 15° with the central plane of the body, which can adapt to the operating direction of the human hand. It can also reduce the requirements for operating space. The specifications are expressed by the width of the openings at both ends (mm), such as 8 to 10, 12 to 14, etc.; usually it is a complete set of equipment, including a set of 8 pieces, a set of 10 pieces, etc.

The two ends of the torx wrench are ring-shaped, and the inner hole of the ring is formed by two regular hexagons that are concentrically offset from each other by 30°. When in use, after turning it 30°, it can be replaced and re-set, so it is suitable for operation in narrow situations. Compared with open-end wrenches, the torx wrench has high strength and is not easy to slip off during use, but it is inconvenient to put on and take off. The specifications are expressed in closed size (mm), such as 8 to 10, 12 to 14, etc. It is usually a complete set of equipment, including a set of 8 pieces, a set of 10 pieces, etc.

The material and ring hole shape of the socket wrench are the same as those of the torx wrench. They are suitable for bolts or nuts with narrow disassembly or assembly locations or that require a certain torque. Socket wrenches are mainly composed of socket heads, handles, ratchet switches, quick cranks, joints and rods. Various handles are suitable for various occasions. Based on the principle of convenient operation or improving efficiency, commonly used socket wrenches are The specifications are 10~32mm. Many special socket wrenches are often used in motorcycle maintenance, such as spark plug sockets, wheel hub sockets, tire nut sockets, etc.

The opening size of the adjustable wrench can be adjusted arbitrarily within a certain range. The usage scenarios are the same as the open-end wrench, but the adjustable wrench is not very flexible to operate. Its specifications are expressed in terms of the maximum opening width (mm), and commonly used ones are 150mm, 300mm, etc.

A torque wrench is a special tool that can read the amount of torque applied. Its specifications are divided by the maximum measurable torque, and the commonly used ones are 294N·m and 490N·m. In addition to controlling the tightening torque of threaded parts, torque wrenches can also be used to measure the starting torque of rotating parts to check the fit and assembly.

The hexagonal wrench is used to disassemble and install the hexagonal bolts (plugs). Its specifications are represented by the hexagonal opposite side size S, and there are 13 types of sizes ranging from 3 to 27mm. During motorcycle maintenance operations, a set of hexagonal wrenches are used to disassemble and install M4 to M30 hexagonal socket bolts.

②Screwdriver. A screwdriver, also known as a screwdriver, screwdriver, driver or screwdriver, is used to tighten or remove screws. There are many types of it, the common ones are: according to the shape of the head, it can be divided into two types: one-word and cross; according to the material and structure of the handle, it can be divided into wooden handle, plastic handle, clamp handle and metal handle There are 4 types; according to the operation mode, it can be divided into manual, electric and pneumatic.

The commonly used screwdrivers are mainly flat-blade screwdrivers and Phillips screwdrivers, as shown in Figure 1-53.

Figure 1-53 Screwdriver

Slotted screwdriver is also called a slotted screwdriver and a flat screwdriver. It is used to tighten or loosen screws with a slotted head. A slotted screwdriver consists of a wooden handle, a blade body and a blade. The specifications are expressed by the length of the cutter body. Commonly used specifications include 100mm, 150mm, 200mm and 300mm. When used, the corresponding specifications should be selected according to the width of the screw groove.

Philips screwdriver, also known as cross-recessed screwdriver and cross-recessed screwdriver, is mainly used to tighten or loosen cross-recessed screws, wood screws and self-tapping screws. Its specifications are the same as a slotted screwdriver.

Figure 1-54 Hand hammer

③Hand hammer. The hand hammer is also called a dome hammer, as shown in Figure 1-54. One end of the hammer head has a slightly arcuate plane, which is the basic working surface, and the other end is a spherical surface, which is used to strike parts with concave and convex shapes. Specifications are expressed in terms of hammer head mass, with 0.5 to 0.75kg being the most commonly used.

④Hand pliers. Hand pliers are commonly used tools for motorcycle repairmen. They mainly include carp pliers, wire cutters, needle nose pliers, wire strippers, etc., as shown in Figure 1-55.

Figure 1-55 Hand Pliers

The front part of the pliers head of carp pliers has flat and fine teeth, which are suitable for clamping general small parts. The middle notch is thick and long for clamping. Cylindrical parts can also be used instead of wrenches to screw small bolts and nuts. The cutting edge at the back of the jaws can cut metal wires. Since there are two holes penetrating each other on the plier body and a special pin, so The opening of the jaws can be easily changed during operation to adapt to clamping parts of different sizes. It is the most commonly used hand pliers in motorcycle maintenance operations. Its specifications are expressed in terms of clamp length, generally 165mm and 200mm.

A wire cutter is a clamping and cutting tool. Wire cutters consist of a plier head and a plier handle. The plier head includes a tooth opening, a knife edge and a side opening.

The tooth mouth can be used to tighten or loosen nuts; the knife edge can be used to cut the rubber or plastic insulation layer of soft wires, and can also be used to cut wires and metal wires; the guillotine can be used to cut hard metal wires such as wires and steel wires. . The pins of wire pliers are fixed relative to the two pliers bodies, so they are not as flexible as carp pliers when used, but the effect of cutting wires is worse than carp pliers. Commonly used specifications mainly include 150mm, 175mm, and 200mm.

Needle-nose pliers are also called trimming pliers. Because of its slender head, it can work in a smaller space. The one with a cutting edge can cut small parts. Do not use too much force when using it, otherwise the jaws will deform or break. Its specifications are expressed in terms of clamp length, and the commonly used specifications are 160mm.

Wire stripping pliers are suitable for stripping plastic and rubber insulated wires and cable core wires. It consists of a knife edge, a crimping port and a clamp handle. The clamp handle is covered with an insulating sleeve with a rated working voltage of 500V.

⑤Steel ruler. The steel ruler is made of stainless steel sheet, with dimensions engraved on the ruler, as shown in Figure 1-56.

Figure 1-56 Steel ruler

Steel rulers generally have four length specifications: 15mm, 200mm, 300mm, and 500mm, and their measurement accuracy can generally only reach 0.2~0.5mm. If you want to use a steel ruler to measure the outer or inner diameter of a part, you must use it with a caliper.

Figure 1-57 Caliper

⑥Caliper. There are two types of calipers for measuring outer diameter and inner diameter, as shown in Figure 1-57. Calipers that measure the outer diameter can be used to measure the thickness, width and outer diameter of parts, and are called external calipers. Calipers that measure the inner diameter are used to measure hole diameter and groove width, etc., and are called internal calipers.

⑦ Square ruler. A square ruler is also called a curved ruler, as shown in Figure 1-58. Its inner and outer corners are perpendicular to each other. Squares are used to check right angles, marking lines and installation positioning. The specifications of the square are expressed by the dimensions of the long side and the short side. For example, a square of 250mm×160mm means a square with a long side of 250mm and a short side of 160mm.

Figure 1-58 Square square

⑧Thickness gauge. Thickness gauge is also called feeler gauge or gap gauge. It is composed of a set of thin steel sheets nailed together at one end. Each piece is engraved with the size of its own thickness, as shown in Figure 1-59. Motorcycle mechanics often use it to measure the gap size between mating parts, or use it in conjunction with a straight ruler and contour blocks to check the flatness error of the workbench surface. Its working dimensions are generally 0.02mm, 0.03mm,..., 1.0mm, and the measurement accuracy is 0.01mm.

Figure 1-59 Thickness gauge

⑨Vernier caliper. The vernier caliper is a relatively precise measuring tool with a simple structure that can directly measure the inner diameter, outer diameter, length and depth of parts. Vernier calipers can be divided into three levels according to measurement accuracy: 0.10mm, 0.05mm, and 0.02mm. According to the measurement size range, there are various specifications such as 0~125mm, 0~150mm, 0~200mm, 0~300mm, etc. When using, select according to the accuracy requirements of the parts and the size of the parts.

The structure of a common vernier caliper is shown in Figure 1-60. It consists of a main ruler, an auxiliary ruler, a claw and a fastening screw. The inner and outer fixed claws are integrated with the main ruler, while the inner and outer movable claws are integrated with the auxiliary ruler (i.e. the vernier ruler) and can slide on the main ruler. The scale on the main ruler is 1 mm per division in the metric system, and the scale on the secondary ruler is less than 1 mm per division. When the two claws are closed, the zero lines on the main and auxiliary scales should coincide. When the two claws are separated, the engraved lines of the main and auxiliary rulers will move relative to each other. When measuring, according to the misaligned positions of the main and auxiliary rulers, you can read integer millimeters on the main ruler and decimal millimeters on the auxiliary ruler. The fastening screw can fix the auxiliary scale at a certain position on the main scale for easy reading.

Figure 1-60 Vernier caliper

⑩Percentile scale. A dial gauge is a measuring tool that uses a differential sleeve to read 0.01 mm. The measuring accuracy of a dial scale is higher than that of a vernier caliper. According to their uses, they can be divided into outer diameter centimeters, inner diameter centimeters and depth centimeters, among which the outer diameter centimeters are the most commonly used.

The outer diameter scale is used to measure the outer diameter, length and thickness of parts. It is divided into various specifications according to the measurement range: 0~25mm, 25~50mm, and 50~75mm.

The outer diameter micrometer is composed of a bow frame, a measuring axis screw, etc., as shown in Figure 1-61. The screw is a right-hand thread with a pitch of 0.5mm. There are also screws with a pitch of 1mm. One end of the screw is a cylindrical measuring rod, which is hardened and polished and installed in a fixed sleeve on the bow frame. Its end face and anvil measure The faces are parallel.

Figure 1-61 Outer diameter centimeter

One end of the fixed sleeve is connected to the bow frame, and the other end has internal threads that can match the screw rod. This enables the screw to move axially at the same time during rotation. There are dimensional engraved lines on the outside of the fixed sleeve. The distance between the engraved lines is 1mm. The engraved lines on both sides of the middle are offset by half a grid (0.5mm).

The differential sleeve is placed on the fixed sleeve and connected to the measuring axis screw. When the screw rotates, the differential sleeve can move on the fixed sleeve. There are circumferential equidividing lines on the conical surface of the differential sleeve. When the screw pitch is 0.5mm, it is divided into 50 equal parts; when the screw pitch is 1mm, it is divided into 100 equal parts, so every time the differential sleeve rotates one step, the screw moves 0.01mm axially.

There is a friction ratchet on the other end of the screw. When the ratchet rotates, it drives the screw to rotate until the measuring surface of the screw is close to the part, and the screw stops rotating. If the ratchet is rotated again, it will make a sound, which means , has been in contact with the measuring surface and reached the appropriate measuring force.

Percent indicator. The dial indicator is the main measuring tool used to check the size and shape errors of parts in parts processing and machine assembly, as shown in Figure 1-62. It is often used to measure the flatness and straightness of the part surface, the parallelism between two parallel surfaces of the part, and the roundness and circular runout of circular parts. The measuring range of the dial indicator has three specifications: 0~3mm, 0~5mm, and 0~10mm.

Figure 1-62 Dial indicator

The lower end of the measuring shaft is equipped with a measuring head. During measurement, when the measuring head touches the surface of the part to be measured, the measuring shaft can move up and down. Every time the measuring axis moves 1nm, the pointer rotates a full circle, and the engraved lines on the dial divide the circumference into 100 equal parts. Therefore, when the pointer swings one division, the measuring axis moves 0.01mm, so the measurement accuracy of the dial indicator is 0.01mm.

(2) Special tools

In the process of disassembly, inspection and repair of motorcycles, in addition to general tools, special tools must also be used. Only by using special tools correctly and appropriately can you avoid damaging the machine parts and ensure reasonable and accurate disassembly, adjustment and assembly.

Special tools commonly used in motorcycle maintenance include clutch assembly tools, piston ring clamps, piston pin pressure removers, piston ring assembly and disassembly pliers, crankshaft pullers, magneto pullers, Spoke wrenches, valve core wrenches, spark plug socket wrenches, exhaust pipe wrenches, piston top dead center measuring tools, stoppers, tire levers, tubeless tire repair glue guns, etc.

①Clutch assembly tools. When disassembling a motorcycle clutch, it is difficult to complete without special tools, especially the pressure plate fastening screw on the disc clutch cannot be tightened. Commonly used clutch assembly tools are shown in Figure 1-63.

Figure 1-63 Clutch assembly tool

When assembling, first install the clutch spring in the spring hole seat of the flywheel, place the upper and lower pressure plates, and install the positioning mandrel on the lower pressure plate. (Insert the four sides of the positioning mandrel into the square hole of the lower pressure plate), put on the spline gear sleeve, and then install the drive piece and the upper pressure plate. Screw the bolts into the screw holes of the flywheel pin (at least 5 screws should be screwed in), turn the lever clockwise to compress the spring until the upper pressure plate contacts the end face of the flywheel pin, first install and tighten the 4 screws, and then remove the tool , install the other two screws and tighten them.

② Piston ring clamp. When assembling the cylinder, in order for the piston assembly to enter the cylinder smoothly, the piston ring must first be compressed so that the outer circumferential surface of the piston ring is flush with the outer circumferential surface of the piston. A commonly used piston ring clamp is shown in Figure 1-64.

Figure 1-64 Piston ring clamp

When assembling, first turn the wrench to open the clip and fit it on the outer diameter of the piston ring of the piston assembly, then turn the wrench to make the The clamps close and compress the outer circumference of the piston ring so that it is flush with the outer circumference of the piston. Place the cylinder on the piston assembly and push down until the piston rings enter the cylinder. Repeat the above action until all piston rings are installed in the cylinder, then loosen the wrench and remove the piston ring clamp.

Figure 1-65 Piston pin pressure remover

③ Piston pin pressure remover. The fit between the piston pin and the piston is generally tight. Do not knock it during disassembly to avoid bending and deformation of the connecting rod. The piston pin pressure remover is shown in Figure 1-65.

When disassembling, put the supporting ring on the piston so that the ejector rod enters the inner hole of the piston pin, and turn the lever clockwise until the piston pin is completely pressed out.

④Assemble and disassemble the piston ring pliers. When assembling and disassembling the piston ring, be sure to use special tools and do not pull it hard with your hands to avoid breaking the piston ring or even damaging the piston. Install and disassemble the piston ring pliers as shown in Figure 1-66.

Figure 1-66 Assembling and disassembling piston ring pliers

When using, put the piston ring into the pliers ring, align the opening of the piston ring with the top of the pliers handle, and hold the pliers firmly handle, the piston ring can be opened, so that the piston ring can be installed into the piston ring groove, or the piston ring can be removed from the piston ring groove.

⑤Crankshaft pull-in device. When repairing an engine, the pulling method is generally used to install the engine crankshaft assembly into the crankcase. The crankshaft puller is shown in Figure 1-67.

Figure 1-67 Crankshaft pull-in device

When using it, press the washer against the end face of the crankcase body, put the screw sleeve on the threaded end of the crankshaft, use a wrench to pull the sleeve, and use another Turn the wrench on the nut and slowly enter the crankshaft into the crankcase.

⑥Magneto puller. A commonly used magneto puller is shown in Figure 1-68.

Figure 1-68 Magneto puller

When using it, screw the screw sleeve into the internal thread of the magneto (left-hand rotation), pull the movable lever to push the ejector into the center hole of the crankshaft and continue to pull the movable lever to remove the magneto.

Figure 1-69 Spoke wrench

⑦ Spoke wrench. The spoke wrench is used to turn the spoke nut and adjust the axial and radial runout of the rim as well as the spoke tightness. There are round spoke wrenches and plate spoke wrenches, each with 6 openings of different sizes to accommodate various spoke nut sizes, as shown in Figure 1-69.

⑧ Valve core wrench. The valve core wrench is used to disassemble and install tire valve cores and repair valves. It consists of die, tap and wrench. The tap is used to repair the internal thread of the valve, and the round die is used to repair the external thread of the valve.

The die pitch is 0.8mm, the tap pitch is 0.75mm, and the square opening of the wrench is 2.1mm, as shown in Figure 1-70.

Figure 1-70 Valve core wrench

Figure 1-71 Spark plug socket wrench

⑨ Spark plug socket wrench. The spark plug socket wrench is used to disassemble and install the spark plug, as shown in Figure 1-71.

When in use, the round rod is inserted into the round hole of the sleeve to act as a plate rod. Due to the different specifications and sizes of spark plugs, the sizes of spark plug socket wrenches are also different. The sizes of various spark plug socket wrenches are shown in Table 1-10.

Table 1-10 Spark plug socket wrench dimensions (mm)

⑩ Exhaust pipe wrench. The exhaust wrench is used to disassemble and install the exhaust pipe nut, as shown in Figure 1-72. The thickness of the exhaust pipe is generally 4mm, and other relevant dimensions are determined according to the diameter of the exhaust pipe nut.

When in use, place the hook of the exhaust pipe wrench into the groove of the exhaust pipe nut, place the arc surface against the outer surface of the exhaust pipe nut, and pull the exhaust pipe wrench firmly. to loosen the exhaust pipe nut. You can also use a hammer to hit the end of the wrench to loosen the exhaust pipe nut, and then pull it by hand.

Piston top dead center measuring tool. The piston top dead center measuring tool consists of a measuring head, a sleeve, a watch clamp screw and a dial indicator, as shown in Figure 1-73.

Figure 1-72 Exhaust pipe wrench

Figure 1-73 Piston top dead center measuring tool

When using, install the sleeve into the spark plug mounting hole middle. In conjunction with a dial indicator, the ignition advance angle can be measured more accurately.

Stop. The stopper consists of cylindrical pins, top plates, rivets, hook plates, fixed rods and other parts, as shown in Figure 1-74. When tightening the magneto fixing nut and the small sprocket fixing nut, you can use this tool to fix the magneto flywheel and the small sprocket to prevent them from rotating and causing difficulties in disassembly and assembly.

Figure 1-74 Stopper

Tire lever. Hand tire levers are used to disassemble and install tires of various specifications. They are used in combination with 2 to 3 levers. Select the appropriate size lever according to the tightness of the tire steel edge. There are two types: curved mouth and straight mouth, and the handle is round or flat. It can also be made of spring steel plate cut into strips, bent and ground, as shown in Figure 1-75.

Figure 1-75 Tire lever

Tubeless tire repair glue gun. When a tubeless tire is punctured by a nail or sharp object (not exploded), you can use a tubeless tire repair glue gun to drive the rubber bullet into the puncture, and use the elasticity of the rubber itself to seal the puncture to achieve high air tightness and sufficient tolerance. Air pressure without leakage. Its appearance is shown in Figure 1-76.

Figure 1-76 Tubeless tire repair glue gun