12 Tips to make your motorcycle run forever

Go out on your own terms. That's how you want to decide it's time to trade in your old bike for a new one—not while you're suddenly stranded on the side of I-Something with (pick one): 1. a munched valve train; 2. a locked tranny; 3. a blown wheel bearing; 4. a dead charging system; or 5. any combination of the above.

Photo by Bill Andrews

Of course, bad stuff like that can happen, but it doesn't have to. In fact, if you treat your bike right, you can considerably reduce the wear and tear that makes new bikes into old bikes—or opens the door for catastrophic failure.

The secret? A sensible, 12-step maintenance program.

Here's how to make sure you get tired of your bike before it tires of you.

1. Follow the recommendations in your manuals

It may be hard to admit, but—believe it or not—the original manufacturer probably knows more about your motorcycle than you do.

Luckily, factory engineers are happy to share much of what they know about your bike in your owners manual. It will advise you on oil type, maintenance schedules, service procedures and more. Read it, study it, memorize it.

In many cases—especially if you plan to do more sophisticated maintenance—you'll also want a full-on service manual. The service manual generally includes everything a shop mechanic needs to know to rebuild every part of your motorcycle, plus stuff like hard-to-find torque values for every bolt on your bike.

A factory service manual might cost $40 to $100 or more. Cheaper options might include a shop manual from a third-party publisher, such as Clymer or Haynes.

2. Break it in right

The most critical miles of your motorcycle's life are the first few hundred, then the next couple thousand. If you don't treat your bike right during these early stages, you could regret it later.

Each bike comes with its own list of guidelines to follow for break-in. Some boil down to, "Ride it gently," while others can be complex programs that involve limits on maximum RPMs for a certain number of miles.

Some bikes even call for one type of oil to be used for break-in, and another after that.

Where do you find this information? Your manual.

3. Change the oil

You hear it all the time: Scheduled oil changes—of the right oil—are the best way to make your engine last.

That's because it's true.

Every motorcycle engine has lots of hard parts that whirl around at frenetic speeds. And the only thing that keeps them from grinding themselves into metal filings is a thin layer of quality oil. When oil breaks down, it can't do a quality job.

So change it often, according to the manufacturer's recommended schedule—or even more often if you ride in dirty or dusty environments.

What kind of oil should you use? That can be a heated question, particularly if you frequent many enthusiast websites, where you can encounter a dizzying array of recommendations about what viscosity, specification (car or motorcycle) or type (conventional or synthetic) of motor oil is best.

Your best bet? Check your owners manual.

4. Clean the air filter

What goes in your motorcycle doesn't always come out. And a lot of what goes in passes through your air filter.

That means if your air filter isn't clean, or, in some cases, properly oiled, you could be cutting off airflow to the cylinders and even allowing in foreign abrasives (dirt, dust or worse), where they can grind away at your valves, internal bearings and cylinders.

So do yourself a favor. When it comes to air-filter maintenance, follow the recommended schedule as a minimum. And if you ride in particularly dusty or dirty environments, clean or replace the filter more often. often.

5. Air up

Running the wrong air pressure in your motorcycle tires can negatively affect everything from fuel mileage to handling. It's not only wasteful, it's downright dangerous.

By maintaining the correct air pressure in your tires (check it once a week with a reliable gauge), they will last longer. And considering they are your bike's sole connection to Mother Earth, the rest of your bike will thank you, too.

6. Keep your bearings

The rule here is simple: Grease your bearings.

New dirtbike buyers pick up this habit early, since many motocross bikes roll off the showroom floor already needing a healthy slathering of grease in areas such as the steering-head bearings and suspension linkages. But street riders need to keep their bikes lubricated, too. While the sealed bearings on modern streetbikes are relatively maintenance free, exposed areas such as suspension linkages need routine care.

Even if you grease religiously, the time will come when you'll have to replace key bearings. So check them periodically.

You can test your steering stem bearings by raising the front wheel off the ground with a stand. If you feel any notchiness when you turn the handlebars, or notice any play when you push on the fork back and forth, replace the bearings.

Likewise, if you feel any play around the front or rear axle, the wheel bearings need to be replaced immediately.

Another critical pivot point is the swingarm. It shouldn't move side-to-side.

The scary thing about bearings is that when they start to go, they go fast—sometimes with catastrophic results. Never put off replacing a bad bearing.

Also in the lubrication category, many bolts benefit from a bit of anti-seize coating when re-installed. Examples include the axles, swingarm bolt, linkage bolts and motor-mount bolts.

7. Watch your drivetrain

Fresh oil and a clean air filter generally will keep your engine and transmission running right, but that's only two-thirds of your bike's mechanical make-up.

The rest is the drivetrain—the chain, belt or shaft that transfers power from your transmission to your rear wheel.

Depending on what type of final drivetrain you're running, you'll want to keep an eye on chain stretch, sprocket wear, belt cracking, or the condition and amount of oil in the shaft housing.

Chain drive systems generally are the most maintenance-intensive, although if you run a sealed chain (O-ring or some variation) and don't run aluminum sprockets (which are light, but wear relatively fast), you'll probably find a periodic minor adjustment is all you need.

8. Protect your charge

A new battery starts dying the second you use it. However, its life can be a long one if you keep it and your charging system in good shape.

The best thing to do to extend battery life is to keep it charged during downtime, preferably with a trickle charger.

The other major issue with batteries is letting the electrolyte solution get too low. Low levels expose the internal plates, reducing capacity and increasing heat.

If you can, eliminate this problem with a sealed, maintenance-free battery.

9. Look for quality

Every one of us enjoys tricking out our motorcycles, adding this or that to change performance, up the style factor or otherwise make it our own.

However, when considering aftermarket parts, evaluate whether they have at least the same workmanship standards of original equipment. If not, they may not last as long.

Bottom line: Choose your bling wisely.

10. Check, please

If it works for airplane pilots, it can work for you.

We mean, of course, going through a pre-ride checklist. That's the best way to find little problems before they become big ones.

Bikes vary (yep, consult your manual), but, generally, you'll want to check: the level of both the motor and transmission oil; tire air pressures; fuel or brake-fluid leaks; bolt tightness; electrical switches and controls.

If something is wrong, fix it.

11. Ride it right

It may make you feel like a race hero if you power-shift your motorcycle without feathering the clutch or backing off on the throttle, but your transmission will grumble—literally.

Likewise, braking easy, accelerating steadily and turning smoothly will help lots of parts last longer.

You can be rough with your bike, but you'll need to be sure you're ready to do more maintenance.

12. If it ain't broke...

Just ride it! Too often, we get anxious to tinker with our pride and joy and start turning wrenches just to scratch that itch.

Generally, you're better off just enjoying another long ride.

Which is, after all, the whole point.

Source: amadirectlink.com

Motorcycle maintenance 101

Cables

In order to avoid any cable ripping or sticking after every off road ride disconnect the throttle cable and remove the throttle from the bar. Clean the bar with some paper and rub grease over it. Put the throttle back, oil the throttle cable and the clutch cable using a special lube spray. You can find it in any motor shop.

Tires

Air pressure must be analyzed obsessively as the tires condition. Don’t wait until you fall down!
If the tire is flat (worn out), replace it! I know it’s expansive but it could mean the difference between 110mph knee down or knee out. Air pressure will be fitted to your riding style. For radial tires, lower pressure is used for aggressive riding and higher pressure for every day use. In diagonal tires it is the exact opposite because of the tire tendency to heat up. Higher air pressure helps the tire to stay cool by reducing the amount of inner layer movement and inner friction.

Drive chain

Your drive chain needs regular attention ever 300 miles because it is exposed to dust, rain and also subject to hard acceleration and very cool wheelies. You have to clean and lube it every 300miles and adjust its tension it when it gets loose.

Lubing your chain

Clean the drive chain with petrol, WD 40 or use a designated cleaning spray. After you got it cleaned up, lift the back end of the bike using the side peg, spin the wheel and spray chain spray on the inside of the chain. Wipe up the rear wheel and tire.

Adjusting a drive chain’s tension

Spin the back wheel and find the tightest point in the chain, then take a Tape Measurement place it on the swing arm and measure the amount of free movement. Loosen up the back wheel rod and use the pulling mechanism. Remember to pull both sides equally.

Wheels

Just remember after every off-road ride to clean and spray some WD 40 on them. using a 6mm wrench, knock on the spokes to check tension. If they feel and sound loose, pull them by turning them evenly about half a turn.

Battery

The idea behind the battery is making use of chemistry. Basically two led plates with sulfur acid and water between them. The acid is slowly entering the plates leaving only water between the two. The battery is constantly charged so the acid is returning to its place. The amount of acid in the battery is checked by a concentration gage. Due to evaporation, you may, from time to time, need to add water to the battery (distilled only), however, you should never add acid. Newer batteries are sealed anyways and they are gel (or nickel – just like your cellphone) based although the same principal applies to all batteries.

Brakes

Brakes are complicated to maintain and a lot of workshops just dont know how to do it right.
Paskal low: pressure =force*area of force. The pressure in both ends of the system (the master cylinder and the caliper) is identical, the area in the master cylinder is small so we should probably use more force in the lever.
Right? No! The lever moves almost half an inch but the brake pad hardly moves at all. The lever also uses a crane effect. It sounds complicated but it isn’t, trust me.
Now let’s replace the pads:
* open the two bolts that hold the caliper
* remove the pads
* using some white paper and brake cleaning spray, clean the pistons (they are already pointing outside)
* press them in using a wrench and the old pad
* clean the disk and the calipers pines using the spray.
* rub the pines with ATE grease (non oily)
* put the new pads in the caliper. Don’t forget any extra parts
* close the caliper with a torque wrench in 35 n/m
* take a can of brake fluid, open the brake fluid tank (on the bar) and the nipple on the caliper
* suck the brake fluid out of the caliper using a vacuum machine and at the same time add fluid to the tank
* When a fresh fluid starts to come out of the caliper close the nipple
* close the tank
* clean the system using only water
Brake fluid is the ultimate paint killer. Don’t let any on your paint. If some drips on your bike, immediately use lots of water and a clean towel to remove it.

Air filter

The best way to destroy an engine is to remove its air filter. Fresh sand and dust will cause an interesting effect inside the cylinder. Cleaning the air filter is a must after every off road ride and this is how to do it:
* First clean the air box area before opening it up.
* open the box and clean it from the inside using some fuel, then drain the tub that is connected to it from the bottom.
* Carefully remove the filter and clean its rails.
* wash it in some soap water and let it dry .
* lube it in an air filter spray or some engine oil.
* squeeze it a bit and put it back after rubbing grease on the sides for good selling.
* remember to close the box correctly.

Suspension

Basically if you want to stay in one piece while scrapping your elbows knees and ears, you have to adjust your bike and the suspension would be a good place to start.
Why?
A motorcycle is a light machine and as such is highly sensitive to road conditions and riding style. The bike has to be as stable as possible during your cunning stuns while running away from the cops. Think about it. A shivering platform is not very useful when you are being chased by a helicopter.
How?
There are 3 main adjustments for you to perform. Actually there are more but leave them to the pros.
Preload - Inside your front forks there are (how surprisingly) springs. In the back you probably already noticed it. Load your ass on the bike. Notice the sag. Now ask a friend to measure it using a meter. In a road bike the sag should be aprox: 20-35mm in the front and 5-12mm in the rear. offroaders should have more.
Compression damping - The rate of compression in the shock. To soften or harden it up just turn the screw on top of the fork. This will close or open the bleed hole inside. In order to further change the setting, you will have to open the fork and replace the metal shim inside.
Rebound damping - Controls the rate of the shocks return and is being adjusted at the bottom of the fork. Other settings ride-height,top-height,deck-height,oil thicknes ect'.

Carburetors

Every giser knows what carburetors are there for but not many know how it is build and how to adjust it.
There are two common carb types: flat slide and c.d.
Flat - The simpler type, the volume of air passing through the venture (the carb bore) is controlled by a throttle slide and the bore itself stays fixed. This carb is used in two strockers and race bikes.
Constant depression - The most common and is used in most of the road bikes. The bore is opening and closing by the engines manifold depression which is controlled by a butterfly throttle.
Tuning
Warning: do not try to tune your bike yourself. This could lead to engine failure. Excessively lean air\fuel mixer will operate as a burner and just burn the engine from the inside. Before you try to tune the carbs, please make sure the air filter is clean, the ignition system must is ok and the throttle cable is adjusted.
Tuning slides:
float height - The level of fuel in the float chamber .that effects on the amount of fuel that will drown from the main jet to the engine. Open the plug in the bottom of the float chamber and fit a plastic tube to it. Now lift the other end of it in the air and watch the fuel level. It has to be approx 1mm lower from the chambers gasket. If it is too low or high open the chamber and bend the float’s metal tang.
Pilot jet - Affects the low revs and way to adjust it is simply to find the point that engines revs are the highest. Than lower them using the idle rev screw and repeat the process
throttle valve cut-away - On modified carbs or engines there could be a problem of too much air in a case of sudden throttle opening. From idle speed, try enriching the pilot mix (the screw with the spring).
Needle and needle jet - The jet and its needle suffer from wear due to the fuel that flows through them. Simply replace them and adjust the needle by clipping it in the middle groove. You can work your way from there. The final tuning is performed according to the manufacture table and the engine’s emissions.
Tuning c.d.
is the same as slides in a case of multiple carbs you have to adjust them in synchronization by using a vacuum gauge.
Mixture screw:1500-3000rpm
pilot air jet:2000-5000rpm
needle:2500-8500rpm
main jet:7500-14000rpm

Most sport bikes today use fuel injection systems and combined with a computer based engine management system (like Dynojet’s power commander) to not require any maintains at all. Changing settings is a simple matter of loading a new map to the computer using your laptop.

Emissions

The shit that comes out through the exhaust is the most accurate indication about engine problems, carb adjustments, ignition problems and generally world peace.
The engine sucks air through the air filter and fuel from the gas tank.
They mix in the carb and become a mixture in 14.7:1 ratio. That means that when 14.7 kg of air enters the combustion chamber only 1kg of fuel had also entered.
This mixture is called ‘stochiyometric’ and it is used for cleaner combustion . For best performance we need to use more gas (13:1). lets explain a little about the stochiyometric Mixture:
the outside air has only 21% O2 and the rest is N2 (78%) and CO2 (1%)
the fuel in a good day is HC.
The emission:
what the problem you ask ? It’s very simple : O2 comes from the outside air, HC comes from the fuel tank, together they become CO2 and H2O right? Not exactly. The final emission contains HC, CO, O2, CO2, H2O and NOX. The last one is created only in high temp engines that means in all the new ones.

HC - fuel that didn't burn it is measured in ppm part per milion there reading is 50-350ppm
NOX - is created from the N2 in the air
O2 - oxigen that didn't burn (0.5-2%)
CO - is basicly co2 that didn't manage to find another o (0.5-2%)
CO2 - 13-15% and the bigger the better . it is the indication for a good combustion
N2 - does not effect the combustion (71%)

Source: galratner.com

Saving Money Maintaining Your Motorbike

While the old adage "if it ain't broke, don't fix it" holds, it's the thorough checking that "it ain't broke" that counts. Many modern bikes have very long service intervals, and are vastly more reliable than machines of the past. But don't let this make you complacent, regular checks are essential to the well being of your bike and yourself.

Easy scheduled maintenance

Doing the simple work yourself not only keeps your bike running well and safely, it saves you money - especially if you choose pattern service parts as an alternative to their hard to get and expensive 'Genuine' counterparts. Often made in same factory as the originals, pattern service parts are generally as good as or better than original equipment.

While these recommendations are applicable to most motorcycles, always check manufacturer's recommendations for correct service intervals for your machine.

Daily checks

  • Lights, indicators and horn
  • Speedometer
  • Tyres and tyre pressures - valve caps that indicate correct pressures are available
  • Fluid levels - oil and coolant if applicable. Quality synthetic oil should be used for newer performance bikes, semi-synthetic for older bikes. A specific quality motorcycle oil like 'Rock Oil' should always be used
  • Chain - if you're doing 100 or more miles per day this should be lubricated and adjusted as necessary
  • Steering Does it operate freely without notches and uneven feel? Does it interfere with the operation of any cables at full lock?
  • Kill switch functionality
  • Side and centre stands - do they return to their correct position for riding?
  • Brake hoses - can you see any chafing or banjo bolts causing weeping?

Weekly or 200 miles (whichever is sooner)

All the above, plus:

  • Check oil level - does it require topping-up?
  • Check tyre pressure - check with an accurate gauge
  • Check battery - if not maintenance-free, then check electrolyte level and top up with distilled water if necessary. If you have an alarm or immobiliser fitted it may be worth giving it a charge (this is especially true if the bike is not being used regularly). The best solution is getting an intelligent charger, and having it plugged in permanently whilst the bike is garaged for any period of time. A battery left uncharged will have a shorter life
  • Check control cables - lubricate as necessary
  • Check brakes - pads and disks should be checked for wear and replaced if necessary; check and top-up fluid. Adjust drum brakes as necessary
  • Make a full visual inspection - check for loose nuts & bolts and spokes if applicable. Fork seal leaks and any other oil leaks.

Monthly or 1,000 miles (whichever is sooner)

All the above, plus:

  • Check spark plugs - clean and adjust or replace, anything other than a light/medium brown deposit may indicate problems
  • Check control cables - adjust free play
  • Check Idle speed - adjust as necessary
  • Lubricate control lever pivots

Every 3 months or 2,500 miles (whichever is sooner)

All the above, plus:

  • Change oil & filter
  • Change air filter
  • Check wheel and steering head bearings - grease and replace if necessary
  • Check exhaust system for leakage

Every 6 months or 5,000 miles

All the above, plus:

  • Adjust carburettor synchronization - if applicable
  • Check overflow pipes - replace any that are blocked or missing

Every 12 months or 10,000 miles

All the above, plus:

  • Replace spark plugs
  • Check suspension linkages - for play, replace linkage, bearings, bushes as necessary

Laying up a bike over the winter:

  • Regularly charge the battery - better still, invest in an intelligent charger
  • Leave on the main stand - if your bike doesn't have one, kits are available for most bikes. Or invest in at least a rear paddock stand to get the weight of the bike off of the tyres, which should be kept correctly inflated
  • Consider draining the petrol as this can deteriorate over time and can, in extreme cases, evaporate leaving a nasty deposit which can block the carburettors. At least turn off the fuel tap and run the engine until the float bowls are empty. Fuel stabilisers are available that can help with this
  • Wax well and lubricate - all parts that generally need lubricating. Make sure the bike is completely dry, then cover with a dust sheet and keep somewhere dry, preferably not in the same room as a tumble drier or other condensation causing machinery. If you have to keep it outside, then invest in a good quality, breathable waterproof cover and cover the exhaust outlets with plastic bags

A quick guide to some common service parts:

  • Brake pads - Generally for road use brake pads are available in two types: GG and HH, related to the friction coefficient of the braking material. HH offers more stopping power for a given force on the brake lever than the GG. But that doesn't make HH pads better - it's more a matter of balance, taste and riding style.

    Some people find HH pads too 'grabby', especially on lightweight machines. Don't fit HH pads to the rear of bike and GG to the front, this will make the overall braking balance too rear biased, which isn't good. However many people find the reverse: HH on the front and GG on the rear very comfortable and effective.

    Many newer sports bikes should only use HH pads, so check the manufacturer's specifications. A noticeable downside to using HH pads is that they tend to wear the brake rotor more quickly.

  • Chains and Sprockets - there's a lot of misleading information given about chains and sprockets (sometimes even by manufacturers promoting their own products), whether X-ring lasts longer than O-ring, or whether one manufacturer is better than another.

    It's actually a question of your riding style, how much use your machine gets, your weight, if you lubricate and adjust the chain correctly, the weather and road conditions. Suffice to say, if you pull wheelies, weigh 35 stone, don't oil or adjust your chain and only ride on wet salted roads your chain won't last very long! That said, if you don't do many miles in a year, you may find that an X-ring will last you longer than an O-ring - or if you ride like Barry Sheene, why bother buying an expensive heavy chain that will cause extra drag?

    On a modern sports bike fitting a new chain and sprockets could give you 8bhp over the old ones, sometimes more, possibly about the same as an expensive 'go faster' ignition system, and it'll make the bike feel like new.

Engine maintenance is very bike specific so oil pumps, valve clearances, ignition timings etc. are not mentioned here; refer to manufacturers' guides, and if in doubt don't trust the geezer down the pub who used to have moped in the 70s, seek expert advice.

Source: Whybike.com

Motorcycle Sparkplug Maintenance Tips to keep your motorcycle at peak condition

Sparkplug Guide
Motorcycle Sparkplug Maintenance Tips to keep your motorcycle at peak condition.

Sparkplugs. They do more and can tell you more than you might think.

Typical Motorcycle Sparkplug
Typical Motorcycle Sparkplug

Motorcycle Sparkplug Maintenance

Tip: Correctly reading a spark plug can save you a lot of time and money.


Sparkplugs:

Types

You may of noticed that there are hundreds of types, sizes and brands of spark plugs on the market. But out of that huge selection, only a handful will work with the motorcycle engine you own. Also different brands (NGK, Bosch, DENSO, Champion, Esc) will work better on different types of engines.

As a general rule of thumb, use the sparkplug your manufacturer recommends for your motorcycle (same brand and part number). Unfortunately some spark plugs are very specific to a type of engine and make only for that engine such as the NGK ME8 for $34.23 per sparkplug, compared to the "normal" price of $2-4 per sparkplug.

Reading a spark plug correctly: (clickable chart)

There are two different main ways to read a spark plug. #1. The first way is to just unscrew it out of the engine and take a look at the end of it, matching the chart below. #2. The second way is the same as #1 except you go for a really hard high revving ride on the bike, pull over and then unscrew each plug to read them. (Just make sure to use gloves as they will be very hot).

A spark plug can easily and quickly tell you the condition of an engine (good or poor), how it is running (rich or lean) and how much it will cost to fix it.

CARBON DEPOSITS

Symptoms: Dry sooty deposits indicate a rich mixture or weak ignition. Causes misfiring, hard shifting and hesitation.

Recommendations: Check for a clogged air element, high float level, sticky choke and worn ignition points. Use a spark plug with a longer core nose for greater anti-fouling protection.

OIL DEPOSITS

Symptoms: Oily coating caused by poor oil control. Oil is leaking past worn valve guides or piston rings into the combustion chamber. Causes hard starting, misfiring and hesitation.

Recommendations: Correct the mechanical condition with necessary repairs and install new plugs.

TOO HOT

Symptoms: Blistered, white insulator, eroded electrode and absence of deposits. Results in shortened plug life.

Recommendations: Check for the correct plug heat range, over-advanced ignition timing, lean fuel mixture, intake manifold vacuum leaks and sticking valves. Check the coolant level and make sure the radiator is not clogged.

PREIGNITION

Symptoms: Melted electrodes. Insulators are white, but may be dirty due to misfiring of flying debris in the combustion chamber. Can lead to engine damage.

Recommendation: Check for the correct plug heat range, over-advanced ignition timing, lean fuel mixture, clogged cooling system and lack of lubrication.

HIGH SPEED GLAZING

Symptoms: Insulator has yellowish, glazed appearance. Indicate that combustion chamber temperatures have risen suddenly during hard acceleration. Normal deposits melt to form a conductive coating. Causes misfiring at high speeds.

Recommendation: Install new plugs. Consider using a colder plug if driving habits warrant.

GAP BRIDGING

Symptoms: Combustion deposits lodge between the electrodes. Heavy deposits accumulate and bridge the electrode gap. The plug ceases to fire… resulting in a dead cylinder.

Recommendation: Locate the faulty plug and remove the deposits from between the electrodes.

NORMAL

Symptoms: Brown to grayish-tan color and slight electrode wear. Correct heat range for engine and operating conditions.

Recommendations: When new spark plugs are installed replace with plugs of the same heat range.

ASH DEPOSITS

Symptoms: Light brown deposits encrusted on the side or center electrodes or both. Derived from oil and/or fuel additives. Excessive amounts may mask the spark, causing misfiring and hesitation during acceleration.

Recommendation: If excessive deposits accumulate over a short time or low mileage, install new valve guide seals to prevent seepage or oil into the combustion chambers. Also try changing gasoline brands.

WORN

Symptoms: Rounded electrodes with a small amount of deposits on the firing end. Normal color. Causes hard starting in damp or cold weather and poor fuel economy.

Recommendation: Replace with new plugs of the same heat range.

DETONATION

Symptoms: Insulators may be cracked or chipped, improper gap setting techniques can also result in a fractured insulator tip. Can lead to piston damage.

Recommendation: Make sure the fuel antiknock values meet engine requirements. Use care when setting the gaps on new plugs. Avoid lugging the engine.

SPLASHED DEPOSITS

Symptoms: After long periods of misfiring, deposits can loosen when normal combustion temperature is restored by an overdue tune-up. At high speeds, deposits flake off the piston and are thrown against the hot insulator, causing misfiring.

Recommendations: Replace the plugs with new ones or clean and reinstall the originals.

MECHANICAL DAMAGE

Symptoms: May be caused by a foreign object in the combustion chamber or the piston striking an incorrect reach (too long) plug. Causes a dead cylinder and could result in piston damage.

Recommendation: remove the foreign object from the engine and/or install the correct reach plug.

Sparkplug Caps:

Tip: Don't use decorative or spark arching type sparkplugs.

There are many different styles and types of sparkplug caps. Try to use the sparkplug cap that best matches the angle between the spark plug wire and spark plug itself. No matter what shape the spark plug cap is, is will perform the same.

Try to avoid "decorate" or spark arching type spark plug caps as they will LOWER the power to the sparkplug and you will have a weaker spark on stock systems.


Types of Motorcycle Spark Plug Caps

Sparkplug Gap

Tip: If you use the exact same sparkplug as your motorcycle manufacturer recommends the sparkplug should be (99%) properly gapped to the correct size. Checking a gap only takes seconds to do.

Always check that the spark plug gap is compatible with the engine manufacturers specification. A gap that is too small means that the spark duration will be very quick and the spark will be thin and weak. The consequences of this may be bad starting and high exhaust emission levels. This will result in an increase in fuel consumption. If the gap is set too large, the ignition system will not be able to cope with the demands and a misfire situation will occur. Some wide gap spark plugs have a longer ground electrode to accommodate a wide gap setting. These must be used where specified, as opening up a standard plug to a wider gap setting may result in the electrodes not running parallel to each other. This could result in abnormal and premature electrode wear.

Hot and Cold Sparkplugs

Tip: It is better to fix the problem than to change the sparkplug to patch it up.

Why Hot and Cold Sparkplugs? Using a hotter or colder sparkplug can be just the fix to an engine problem. Very basely, if your motorcycle engine is running hot then try using a colder plug, if it is running hot try a colder plug.

NGK diagram showing insulator and heat range
NGK diagram showing insulator and heat range

Hot Plug

- has a longer insulator nose length
- less heat is absorbed by the plug and transferred to the cooling system
- the plug runs at a higher temperature
- the plug is more prone to pre-ignition (if greater than 850 degrees C)
- NGK BP5ES is hotter than a BP7ES plug.
- An overheated plug will be white with brown spots.

Cold Plug

- has a shorter insulator nose length
- more heat is absorbed by the plug and transferred to the cooling system
- the plug runs at a lower temperature
- the plug is more prone to fouling (if less than 500 degrees C)
- NGK BP7ES is cooler than a BP5ES plug.
- A fouled plug will be black and sooty.

Influences to spark plug temperature

Any of the following situations can increase spark plug temperature:

-Lean air/fuel mixtures
-Increasing compression
-Forced induction (Supercharging, turbocharging or Nitrous)
-Camshaft change
-Advancing ignition timing
-Higher engine speed
-Higher engine load
-Lower air temperature (more dense air resulting in leaner air/fuel mixture)
-Lower humidity (more dense air resulting in leaner air/fuel mixture)

Source: Totalmotorcycle.com

Battery Care Guide

General Care

Motorcycle batteries like being used. They do not like being neglected, unused or uncharged.

If left for any length of time without being charged, even if they are not connected, all lead-acid batteries will go through a natural process of self-discharging. If the battery has reached the stage of being deeply discharged it is often impossible to recover, even if the battery itself is relatively new. If the battery is connected to the bike and the bike has an alarm or immobiliser fitted the time it takes a battery to reach a deeply discharged state can be short, often a matter of days.

Regular charging is the only way to ensure a long life from your battery and work against the natural process of self-discharge. Most intelligent motorcycle battery chargers come with leads which can be permanently fixed to your battery with the battery connector neatly hidden away in the bike. Charging is then a easy matter of plugging the connector in to the charger.

It's worth noting that weather and temperature can affect the rate of discharge and functionality of the battery. Hotter temperatures rapidly accelerate the self-discharging process. However you should be careful not to let the battery go too cold as a discharged battery is less resistant to freezing. A fully charged battery would freeze around -59°C whereas a severely discharged battery can freeze at -1°C.

Cleaning

Sulphation occurs when the lead sulphate (a white substance) is allowed to build up on the plates. It can eventually destroy your battery. To keep the battery from sulphating it's vital to check your bike is working properly, and to keep the battery terminals clean and disconnected when the bike is in storage or not being used for a long period of time. It is important that the battery is regularly charged when not in use.

Electrolyte

The fluid in the battery is called electrolyte. It is a mixture of water and sulphuric acid that causes the chemical reaction which produces electricity. Conventional and Yumicron type batteries need to have their electrolyte checked and topped up with distilled water at regular intervals.

As part of the normal electrochemical processes of a lead acid battery water in the dilute acid is turned into gas and escapes from the cell. This needs to be replaced with either distilled or de-ionised water. Do not use tap water as this has elements which will permanently damage the battery. Once the battery has been commissioned you should never add any further acid as this will seriously degrade the life of a battery.

It is important to maintain the level of fluid as low levels can cause the acid within the battery to become too strong. This can lead to corrosion of the battery's internal components and the battery shorting itself. Maintenance free batteries use processes that quickly re-absorb the gas into the electrolyte and therefore never need topping up.

Charging

Never user a normal car battery charger to charge a motorcycle battery, even for a short time. Car chargers supply far more current than a motorcycle battery can cope with and can very quickly damage the battery plates beyond repair.

Charging is best done with the battery removed from the bike. Conventional and Yumicron batteries should have the plugs carefully removed from top of each cell. When you have removed the battery from the bike and placed it on a level surface it's probably worth giving it a clean, paying particular attention to the terminals and the area between them as any build up of of conductive material between the terminals could lead to current leakage. Bicarbonate of soda and water applied with a toothbrush can be quite effective, but make sure you leave the battery perfectly dry when you're finished cleaning.

When charging the battery you should make sure the area is well ventilated to prevent the buildup of explosive gases. When connecting the battery and charger make sure the charger is turned off to reduce the chance of any sparks. Connect the battery positive-to-positive and negative-to-negative. Charge the battery according to the manufacturers recommendations. Practice caution if the battery becomes hot to the touch, as hot batteries can explode. If the battery does become hot, disconnect the charger and let the battery cool down before recharging.

Always wear safety goggles when working with batteries. Clean away any electrolyte on the outside of the battery. If you come to contact with the electrolyte, wash the effected areas for several minutes. If you get any in your eyes wash them immediately and contact a doctor.

The absolute maximum charge you should use on a motorcycle battery is about 1 amp. Use a voltmeter to test if a battery is fully charged by connecting the positive-to-positive and negative-to-negative, putting a low load (turning on the light and ignition) and taking a reading at the battery. With a 12 volt battery you should expect at least 11.5 volts DC, a 6 volt system at least 5.75 volts.

Types Of Charger

There are many battery chargers available. You should be sure to use a battery charger which is designed for motorcycles, a car charger will deliver too much charge.

Trickle chargers charge the battery continually at a fixed rate. However, they require a watchful eye as they do not have a way of responding when a battery is fully charged. Leaving them to charge excessively can damage the battery.

Taper chargers decrease the amount of current delivered through the battery as the voltage rises. As with trickle chargers they require a watchful eye to avoid overcharging. Both taper and trickle chargers are slow.

Pulse or intelligent chargers monitor and collect feedback from the battery's voltage during the charging process and drop into a standby mode once the battery is fully charged. When the battery naturally discharges to a certain level the charger will go into charging mode and restore the battery to its normal charge. A pulse charger can be left unattended for long periods of time, but you should still carry out periodic fluid level checks.

Source: Motorcycle.co.uk

Motorcycle Battery Maintenace Tips to keep your motorcycle at peak condition.

Motorcycle maintenance is more than doing maintenance on your motorcycle because you have to do it now or it is time to do it right away. On going general maintenance will keep your motorcycle in great condition with little or no unpleasant surprises on the road.

Typical Motorcycle Battery
Typical Motorcycle Battery

Motorcycle Battery Maintenance

Tip: There are dozens of parts on a motorcycle that could be checked on a regular basis and there is nothing wrong with check all those parts. But try to slim the list down to the most important items so you still have time to ride.

The Battery

THE BASICS

First things first. A 12-volt battery is not a 12-volt battery. Twelve volts is just a nominal, convenient term used to distinguish one battery from another. A fully-charged 12-volt battery, allowed to "rest" for a few hours (or days) with no load being drawn from it (or charge going to it), will balance out its charge and measure about 12.6 volts between terminals.

When a battery reads only 12 volts under the above conditions, it's almost fully depleted. Actually, if a battery's resting voltage is only 12.0 to 12.1 it means only 20 to 25% of its useful energy remains. It's either a goner or it has been deep cycled, and a battery can only be deep-cycled a limited number of times before it is indeed dead.

12-volt batteries supply useful energy only through a limited range -- from over 14 volts (when fully charged and unrested) down to 10.5 volts in use/under load (when lights dim, your motorcycle is hard to start). No 12-volt battery will remain at over 14 volts for more than seconds unless it's being charged. The lowest limit is 10.5 volts (used in testing) and obviously unsatisfactory in practical use.


NOTES: Keep in mind that listed voltages are "Resting" Volts.

Maintaining Your Battery

Tip: Check the fluid levels on each chamber. If any chamber is low, carefully top it up. Use only distilled or deionized water, NOT tap water. Tap water has minerals in it that will not do the battery any good.

The humble battery is a very common cause for motorcycle breakdowns! Unfortunately they are awkward to get to and therefore do not get checked as often as they should.

A battery only requires a little monthly maintenance to perform perfectly. Keep the battery charged to 100%, recharging when the lights dim, the starter sounds weak, or the battery hasn't been used in more than two weeks. Other than that, follow this simple check list every month:

- Check the electrolyte level
- Top up only with distilled or deionized water, wear gloves and protective glasses. Top up in a well ventilated area, Beware of fumes.
- Keep the top free of grime
- Check cables, clamps, and case for obvious damage or loose connections
- Clean terminals and connectors as necessary
- Check inside for excessive sediment, sulfation or mossing
- Make sure the exhaust tube is free of kinks and clogs
- Replace caps firmly
- Finish up by testing the battery with either a hydrometer or voltmeter. To extend the service life of your battery, make monthly battery maintenance part of your routine.

Use only distilled or deionized water, NOT tap water. Tap water has minerals in it that will not do the battery any good.

Storage can be hard on batteries. In fact, non-use can leave them unable to hold a charge.

Store your bike in a place that is always warmer than 32 degrees. If your bike is outside remove the battery from your bike and store it in a location that is always warmer than 32 degrees. This will insure that your battery does not freeze and crack.

If you remove the battery from your bike DO NOT store it on a concrete or metal surface, place the battery on a wood or other non-conductive surface. Batteries stored on concrete or metal will discharge over time.

Place a charger on your battery. Trickle charge your battery at least once a month. A battery that is fully charged will have a longer life and is less likely to freeze during cold winter weather.

Safety - Proper Clothing

Always wear a face shield or safety goggles.

Wear plastic gloves to prevent acid burns. An apron or smock will protect your clothes.
Working With Acid

Clean up acid spills immediately using a water and baking soda solution to neutralize (1lb. baking soda in 1 gallon of water).

Make sure the acid container is clearly marked and the work area is well-lighted and well-ventilated.

If sulfuric acid is swallowed or splashed in the eyes, treat immediately. Sulfuric acid in the eyes can cause blindness. Serious internal injuries or death can result if swallowed. Used as an electrolyte, sulfuric acid can burn the skin.

ANTIDOTES: For acid on the skin, flush with water. If acid is swallowed drink large quantities of milk or water, followed by milk of magnesia, vegetable oil or beaten eggs. Do not induce vomiting. Call a poison control center or doctor immediately. For acid in the eyes, flush for several minutes with water and seek immediate medical attention.


Charging Safety

When charging conventional batteries, loosen vent caps and ventilate charging area. A buildup of hydrogen and oxygen in the battery or in the charging area can create an explosion hazard.
If the battery feels hot to the touch during charging, STOP. Allow the battery to cool before charging again. Heat damages the plates, and a battery that is too hot can explode.

NEVER put the red sealing cap back on the battery once you take it off. If you do, gases will become trapped and could explode.

Make sure the vent tube isn't kinked or blocked. Otherwise, gases could build up and explode.

Properly connect the charger to the battery: positive charger lead to positive battery post and negative charger lead to negative battery post. Unplug the charger or turn it off before you disconnect the leads, which will cut down on the chance of sparks.

ABSOLUTELY NO SMOKING, SPARKS OR FLAMES AROUND CHARGING BATTERIES. Charging gives off hydrogen and oxygen, which explode if ignited.

Selecting the Proper Battery

It's easier than you think to buy the wrong battery for your vehicle. Unless your current battery is definitely the original equipment, you're taking a chance by not double checking before you purchase the new battery. You can search for a certain battery, but there are a few general rules you should know before you search.

If the battery for your vehicle is sensor-equipped, remember to replace the sensor at the same time you change the battery.

Never swap a Maintenance Free battery for another battery unless the Applications book says it's OK.

When given the option of several different batteries for your vehicle, choose the one that will give you what you want performance-wise. It's up to you.

Always make sure you have the right battery before you charge and install it. Save yourself the hassle (and money) of having to buy another battery.

Source: Totalmotorcycle.com

Motorcycle Tires – Maintenance Tips

Please don’t ever make the mistake of thinking all motorcycle tires are the same. Each motorcycle requires its own type of tire that’s even further deemed appropriate by its specific use. While that’s all explicit and I talked about it in my previous post about choosing motorcycle tires, there are some general caring practices that can be applied to all tire types.

Good working tires will considerably contribute to the wonderful experience that only motorcycling can afford as well as to a safe ride. Motorcycle tires can also be expensive so you’re well advised to take good care of them.

Below you’ll find 10 tips that will help will help extend the life of any motorcycle tire regardless of its type or use.

Tip #1 - Keep your tires at the right pressure. They will perform better and last longer. Always carry a pressure gauge in your bike and check air pressure at least once a week. Under inflated or over inflated tires will wear out faster and can compromise your safety.

Tip #2 - When mounting new tires, always balance the tire and rim. This will avoid vibration while riding as well as premature tire wear.

Tip #3 – Always “break in” new motorcycle tires. Every new tire could use a good break-in period. This will enhance your tires’ performance over their lifetime of service. After installing new tires on your motorcycle, take the bike out for a few easy and light rides just for the purpose of breaking in the new tires. After the first 100-200 miles, the new tires should be stable enough to accommodate fast accelerations, hard cornering and sharp breaking. Otherwise you could be faced with imbalance, low tire life and differing profiles on both the front and rear.

Tip #4 – When possible, keep new tires out of direct sunlight. Whether they’re on a motorcycle or not, direct sunlight (or more precisely, UV radiation) will chemically change the tire compounds and weaken bonds, dry the tires, and make them brittle ahead of time. The ozone in the air can react with the compounds in the tire too and cause additional unwanted changes. Electric motors contribute to ozone production, so in addition to keeping tires out of sunlight, keep them away from things like large generators or air conditioning units.

Tip #5 - Never mount a front tire on the back of the bike or a rear tire on the front. The front and rear tires of a motorcycle have completely different design profiles.

Tip #6 - Replace motorcycle tires at the same time. If you ride a motorcycle with an old worn tire in the front and a spanking brand new tire in the back, the bike’s stability will decrease and create dangerous driving environment.

Tip #7 - Don’t mix radials with bias-ply motorcycle tires. Each one of these different types of tire gives a motorcycle a specific type of handling characteristic. Mixing them on one vehicle will only create an unstable condition, a rougher ride, and it will decrease the ability to hug corners.

Tip #8 - Clean tires with mild soap solution and rinse with plain clear water. Clean your tires frequently and especially after a long ride or after riding on rough terrain. Oil, gas, and street debris can degrade the tire’s compounds faster than usual. Take the time to clean off the tires so that their treads can a) move the way that they were designed to move, b) maximize grip and friction, and c) stabilize the bike. While cleaning your tires inspect them carefully and look out for cracks and embrittled surfaces.

Tip #9 – During long periods you don’t use your bike - as in winter - don’t outgas the bike’s tires because that will eventually make them brittle. Even if they’re not used, keep your tires at the right pressure.

Tip #10 – Do not overload your bike. Heavy add-ons can have a significant impact on the lifetime, the durability, and the performance of motorcycle tires. If you are planning to add a sidecar, saddlebags and/or other heavy accessories, ask your motorcycle dealer about your bike’s tires and which ones would be most appropriate for the intended purpose.

Source: Worldwidemotorcycles.com

Motorcycle Brake Inspection & Service

Motorcycle brakes, both the disc and drum types, may seem so reliable that they never need maintenance, but a little bit of attention can make them work better and more certainly. By Mark Zimmerman.

Step By Step: How to Change Your Motorcycle's Engine Oil

Get your supplies ready, and expose your engine

Be careful not to scratch the fairing while unfastening and removing it.

© Basem Wasef, Licensed to About.com
Oil changes are of the easiest and most effective ways to prolong the life of your bike, and should be performed every six months or 3,000 miles-- whichever comes first. Carbureted bikes are more susceptible to the ravages of storage since fuel can easily contaminate the engine oil, so be extra vigilant with non-fuel injected bikes.

Before you start, make sure you have the following supplies ready:
  • An allen wrench or screwdriver (for fairing removal, if necessary.)
  • An oil filter wrench (for removing the oil filter.)
  • The appropriate crush washer for your oil drain plug-- this can be purchased from a hardware store or motorcycle service shop.
  • A pair of needle-nose pliers, in case the oil filler cap is hard to reach or tightly screwed on.
  • An adjustable socket wrench.
  • Clean rags.
  • The proper amount of manufacturer-recommended engine oil.
  • A new, manufacturer-approved oil filter.
  • A funnel.
If necessary, remove fairing or bodywork blocking access to the engine

If bodywork surrounds the engine that needs an oil change, you'll have to remove it. Don't worry- this is easier than it sounds.

Bikes often come equipped with small toolkits under their seats; if you can't find yours, use the appropriate Phillips screwdriver and/or Allen wrench in order to unscrew the bolts holding your fairing to the frame.

Be sure to keep all fasteners, brackets and bolts together in a safe place until it's time to put everything back together again.

Unscrew the Oil Filler Cap

If your fingers can't reach, needle-nose pliers should do the trick.

© Basem Wasef, Licensed to About.com

Before draining the engine oil, you'll want to unscrew the oil filler cap (it's usually made of black plastic, with a raised twist tab.) Doing so will allow the oil to drain more quickly.

If the cap is hard to reach or tightly screwed on, you might want to use needle-nose pliers.

Remove the Oil Drain Plug

Be prepared for the potentially hot flow of oil as you unscrew the drain plug.

© Basem Wasef, Licensed to About.com

Place a pan or bucket under the engine and use a socket wrench to remove the drain plug, which is located on the underside of the oil pan.

Be careful during the last few turns, as the oil-- which might be hot-- will start to spill out.

IMPORTANT NOTE: Be sure to properly dispose of used oil at a qualified hazardous waste disposal facility. Dumping used oil is both illegal and harmful to the environment.

Remove and Replace the Crush Washer

Crush washers should never be re-used; always install a fresh one with each oil change.

© Basem Wasef, Licensed to About.com

The crush washer is an aluminum or copper disc designed to deform under pressure, which helps seal the oil drain plug. This part must be replaced after each oil change, and is seen here being separated from the drain plug.

Clean the Oil Drain Plug

Look closely at the oil drain plug (on the right), and you can see small bits of metal adhered to its magnetic tip.

© Basem Wasef, Licensed to About.com

The tip of the drain plug is usually magnetic, in order to attract slivers of metal shed by the engine. While larger pieces are typically found during an engine's break-in period, don't be alarmed when smaller pieces routinely end up stuck onto the edge of the drain plug; just wipe them off with a clean rag.

Remove the Oil Filter


Unless you've got incredibly strong hand grip, you'll probably need a wrench to remove the filter.

© Basem Wasef, Licensed to About.com

While the oil continues to drain, unscrew the oil filter using a filter removal tool, which reaches around what might be a tightly screwed in filter.

Once the filter is off, make sure the filter's O-ring (a band of rubber that fits on the tip to ensure a secure seal) came off with the filter.

Remove and Clean Plastic Mesh Filter

If you don't have a can of compressed air, use a rag to carefully remove fine particles from the mesh filter.

© Basem Wasef, Licensed to About.com

In order to remove larger particulates, unscrew and remove the plastic mesh filter from the side of the engine case.

First, wipe the mesh off with a clean rag so no particles remain. Then, if possible, blow smaller particles off with compressed air.

While the drain plug, mesh filter, and oil filter holes on the engine are exposed, wipe them all down with a clean rag to remove any accumulated sludge, in order to ensure a tight seal.

Lubricate the O-ring of the New Filter and Attach it to the Engine

O-rings on oil filters usually fit snugly because of their squared edges.

© Basem Wasef, Licensed to About.com

Every new oil filter comes with an O-ring; ensure it is seated snugly in the filter and spread a dab of motor oil around its top surface in order to ensure a tight seal.

Then, using your hand, screw the new filter into the engine case. Be sure NOT to use a tool for this part; it's easy to over-tighten the filter and damage the O-ring when using a tool.

Motorcycle Oil Change - Replace Oil Drain Plug & Plastic Mesh Filter, Pour Oil

Long funnels can make oil filling easier.

© Basem Wasef, Licensed to About.com
Once the old oil is completely drained, which should take at least several minutes, use a clean rag to wipe down the drain hole and the mesh filter hole. Screw the oil drain plug (with a new aluminum crush washer) and the plastic mesh filter back into the case.

Use the owner's manual (or markings on the engine) to find out the engine's oil capacity, fill it up with that amount-- minus about one half quart-- by placing a funnel into the oil filler hole.

Screw in the oil filler cap and start up the engine. Let the engine idle for about a minute, then shut it off.

Check the Oil Level

Most bikes have clear windows with which to visually check engine oil level.

© Basem Wasef, Licensed to About.com

After the engine has idled for about a minute, shut it off and wait another minute or so for the new oil to settle from the cylinder heads into the crankcase.

Make sure the bike is perfectly level; if there is a rear stand attached to the bike, remove it so it rests flat on the ground. If the bike doesn't have a center stand, lift it off its kickstand so it sits up perfectly straight. Check the oil window on the side of the crankcase: if the oil is below the center line, top it off until it's perfectly centered. If it's already at the center, voila-- you've just successfully changed your oil!

Source: Motorcycles.about.com

Carburator Rebuild Tips

In the column I do every month, I often give the generic advice to an owner of a puking or blubbering bike to "rebuild your carb." I take it for granted, because it seems like a simple thing to do, and one that I've done literally hundreds of times.

Therefore, it's only fair to pass on the "how-to" stuff to those who need it. And who could need it more than owners of older bikes. Especially people on a budget who buy older bikes and want to get them running right again.


Most of carb rebuilding is nothing more than simple cleaning. Although it's possible to clean a carb body with soapy water and a sponge, we suggest removing the sponge before reinstallation.

Carburetor rebuilding sounds like such a high-tech job, something that would take the better part of a day and require dozens of precision instruments and months of specialized training and experience.

In actuality, all it requires is a bit of patience and a nice, clean working area.

Your friends never have to know how easy it really is, and you can dazzle them with your skill, but ninety-five percent of the time, carb rebuilding is nothing more than taking the darn thing apart and putting it back together.

DIFFERENT KINDS OF CARBS
On most modern bikes, you'll find only Mikunis or Kehin carbs. However, if you're in to vintage or classic bikes, there are a whole bunch of mixers to consider.


Here's an example of a slightly worn slide that's probably re-usable. If the scratches or gouges are worse than this, replace it.

The three major types of carburetors available are Bing (KTM, Maico, most European bikes), Keihin (Honda), and Mikuni for most other Japanese bikes. You'll also find Amals, IRZs and Jikovs on many of the older Euro bikes.

Each one of these five different brands differs in construction, but they all perform the same function and require the same type of maintenance.
Naturally, Bing parts do not fit a Mikuni, Mikuni parts do not fit a Keihin, and Keihin parts fit nothing but a Keihin. If you need parts, gaskets or whatever, take the pieces in question to your dealer and replace them with fresh parts.

DOING IT
First, remove the carb from the bike. Normally, you would remove the top of the carb, pull the slide out and let the slide stay attached to the cable. You can spray a bit of carb cleaner on that later, but for now, just take the carb body over to your work area.

Drain the old fuel out of the carb body and remove the screws that hold the float bowl on. (It'll be held on by a spring clip on the Bing.) Remove the floats, and the float needle and the seat.

Next, remove the idle adjust screw (if it has one) and the idle air screw. Take off the choke lever and carefully remove the choke assembly, with the spring and all the related parts.


The Mikuni is the most popular carb around and the easiest to get parts for.

All the jets come out last. I like to set everything on separate rags on my work bench: the jets on one rag, the choke assembly another, and so forth.

The body is now stripped. Take it and submerge it in a bucket of solvent and scrub it down with a small (clean) paintbrush. Clean off every speck of dirt and crud, inside and out. If you want to get the body totally shiny-clean, dunk it in a bucket of commercial carburetor cleaner. It'll come out looking brand new. Carb cleaner is expensive, however, and you don't really need it. Just make sure that the body is perfectly clean.

Once you're satisfied that the body is clean, do the same thing to the loose parts, taking care not to lose any of them. Remove the top of the carb, the spring and the throttle slide from the end of the throttle.

REPLACING PARTS
No matter what your friends say, the main jet and the pilot jet cannot wear out. Just blow them out with air and/or contact cleaner. Make sure the hole is completely clean. If you peek through it looks less than a perfectly round hole in the jet, it has a build-up of crud in the jet hole. Don't clean the jet holes by running a wire through them, as it can enlarge the holes.


Here's your basic choke assembly. At the bottom of the plunger, you'll find a rubber seal. If it wears out, you'll have problems.

Check the throttle slide, needle jet and jet needle for scuffing or wear, and replace them if they look at all worn. Separate the float needle and its seat, and inspect the tip of the needle for wear, If it has a groove worn in it around the tip, replace the needle and seat as a unit.

The choke system consists of a metal plunger with a rubber gasket at the bottom. Replace the choke plunger if it looks excessively scored, or if the rubber gasket is worn. Treat the idle adjustment screw and the idle air screw the same as the float needle: If the tips are worn to any noticeable extent, replace them outright. Check all related 0-rings and rubber seals; replace them if they look bad.

REASSEMBLY
Basically, put it all back together the way you found it. Snug all the parts down with a wrench or screwdriver, but don't apply excessive force-just slightly tighter than finger-tight will do.


Bing carbs can be found on many older European bikes. Even though the parts look different than the common Mikuni, they serve the same basic function.

Check your float level as per the instructions in the service manual for your bike. Usually the floats should sit parallel to the carb body, with the tang on the float assembly just touching the spring pin on the needle. Do the same thing with the idle air screw (most manuals call for an adjustment of one and a half turns out after lightly seating the screw).

If your float bowl gasket was leaking before you started the rebuild, replace it with a new one.

Finally, reattach the cable to the slide, drop the slide in with the cutout on the bottom facing the back of the carb, screw the top on the carb, and clamp it back in place on the bike.

You have now officially rebuilt your carb; and no, you don't have to tell everyone how easy it was.

Source: Dirtbike.off-road.com

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