Motorcycle Engineering

381 Pages·2021·31.529 MB·English

by  Andrew Livesey

Motorcycle Engineering
Motorcycle Engineering is a primer and technical introduction for anyone
interested in motorcycles, motorcycling, and the motorcycle industry. It
provides insight into how motorcycles are made and operated.
Motorcycles, mopeds, and scooters are important factors in world trans-
port, and they are playing an increasingly important role in transport pol-
icy as we move towards greater environmental awareness. Motorcycles and
scooters give freedom of personal transport that enable large commuter
distances to be covered quickly and easily. Their small footprint offers easy
storage, as only minimal space is required. To celebrate the importance of
motorcycles on the world stage, a brief history is included with a detailed
timeline detailing the development of the motorcycle alongside major world
events.
Written in an accessible fashion, no previous knowledge of engineering
or technology is required, as all technical terms are readily explained and
a glossary and abbreviation list is included. Whether you are an enthusiast,
racer, student, or industry professional, you will surely find this an enjoy-
able read and a handy reference book on your shelf.
Andrew Livesey, MA, CEng, is a lecturer in engineering at Ashford Col-
lege University Centre in Kent, England, when he is not riding his motorcy-
cle, bicycle, or building something in his garage. He is a member of several
motorcycle and bicycle groups, mixing social riding with competition events
when possible. He also enjoys very fast high-performance cars. His Rout-
ledge publications include Basic Motorsport Engineering (2011), Advanced
Motorsport Engineering (2012), The Repair of Vehicle Bodies, 7th edition
(2018), Practical Motorsport Engineering (2018), and Bicycle Engineering
and Technology (2021).

Motorcycle Engineering
Andrew Livesey
First published 2021
by Routledge
2 Park Square, Milton Park, Abingdon, Oxon OX14 4RN
and by Routledge
52 Vanderbilt Avenue, New York, NY 10017
Routledge is an imprint of the Taylor & Francis Group, an informa business
© 2021 Andrew Livesey
The right of Andrew Livesey to be identified as author of this work has been
asserted by him in accordance with sections 77 and 78 of the Copyright,
Designs and Patents Act 1988.
All rights reserved. No part of this book may be reprinted or reproduced or
utilised in any form or by any electronic, mechanical, or other means, now
known or hereafter invented, including photocopying and recording, or in any
information storage or retrieval system, without permission in writing from
the publishers.
Trademark notice: Product or corporate names may be trademarks or
registered trademarks, and are used only for identification and explanation
without intent to infringe.
British Library Cataloguing-in-Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloging-in-Publication Data
Names: Livesey, Andrew, author.
Title: Motorcycle engineering / Andrew Livesey.
Description: Abingdon, Oxon ; New York, NY : Routledge, 2021. | Includes
index. | Summary: “The complex engineering behind the machines is explained
in easy-to-understand terms and supported by 350 images. It covers a range
of motorcycle types, and will be particularly useful for students on motorcycle
and motorsport courses such as those run by the IMI and City & Guilds, as
well as BTEC programmes”— Provided by publisher.
Identifiers: LCCN 2021000799 (print) | LCCN 2021000800 (ebook) |
ISBN 9780367419202 (hbk) | ISBN 9780367419196 (pbk) |
ISBN 9780367816858 (ebk)
Subjects: LCSH: Motorcycles—Design and construction.
Classification: LCC TL440 .L57 2021 (print) | LCC TL440 (ebook) |
DDC 629.227/5—dc23
LC record available at https://lccn.loc.gov/2021000799
LC ebook record available at https://lccn.loc.gov/2021000800
ISBN: 978-0-367-41920-2 (hbk)
ISBN: 978-0-367-41919-6 (pbk)
ISBN: 978-0-367-81685-8 (ebk)
Typeset in Sabon
by KnowledgeWorks Global Ltd.
Contents
Abbreviations and symbols xi
General abbreviations xiii
Preface xvii
1 Power unit – engine 1
Identification 2
Engine performance 2
Engine construction 8
Combustion 25
Cylinder head 27
Short block assembly 29
Induction 31
Exhaust 32
2 Ignition and fuel 35
Ignition system 35
Battery 36
Ignition switch 36
Ignition coil 37
Fuel system 45
Air:petrol ratio 50
Petrol injection 51
Electronic control unit 52
3 Lubrication and cooling 55
Lubrication system 55
The cooling system 65
v
vi Contents
4 Health, safety, security, and the environment 75
Personal health and safety procedures 75
COSHH 86
RIDDOR 86
Miscellaneous topics 93
5 Motorcycle types 95
Motorcycle categories, ages, and licence requirements
in the UK 95
Safety equipment 96
6 Materials for motorcycles 111
Metallic materials 111
Manufacture of steel 112
Annealing and tempering 113
Classifications of steel 113
Alloying metals used with steel in motorcycle frames 115
Work hardening and fatigue failure 117
Properties of materials 117
Frame tubing 118
Reynolds tubing 118
Columbus tubing 120
7 Frames and fairings 123
Frames 123
Fairings 125
8 Electric motorcycles 133
Rules and regulations 133
Electric bicycle construction 136
Health and safety 142
9 Soldering, brazing, and welding 143
Comparison of fusion and nonfusion jointing
processes 143
Aluminium brazing 149
Health and safety and the environment 152
Safety measures 154
General equipment safety 156
Gas-shielded arc welding (MIG, MAG, and TIG) 156
Contents vii
10 Running gear and braking 159
Running gear 159
Suspension and steering 159
Wheels and tires 166
Wheels 168
Tires 169
Braking system 175
Mechanical brakes 178
Hydraulic brakes 181
Drum brakes 184
11 Motorcycle electrical and electronic systems 197
Battery 197
Alternator 201
Starter motor 202
Vehicle circuits 203
Lights 209
12 The motorcycle industry 213
Traditional motorcycle shop 213
Assembly methods: modern retailing 218
Other motorcycle industry services 220
Trade associations 222
13 Reinforced composite materials 225
Introduction 225
Basic principles of reinforced composite
materials 226
Manufacture of reinforced composite
materials 227
Types of reinforcing material 228
Resins used in reinforced composite
materials 230
Catalysts and accelerators 231
Pre-impregnated material (Pre-preg) 236
14 Data 239
The norm 239
Understanding and using data 240
viii Contents
Bar charts and stacking bar charts 242
Pie charts 242
Normal distribution 243
Profit and loss account (PLA) 245
15 Science terminology 249
SI system and common units 249
Decimals and zeros 250
Accurate measuring 251
Capacity and volume 253
Temperature and heat 253
Force and pressure 254
Amps, volts, ohms, watts, and kirchhoff 255
Friction 256
Some common laws of mechanical
engineering 257
Impact and momentum 257
16 Transmission 259
Clutch 259
Gearbox 264
17 Tuning and customizing 275
Modifications 275
Vehicle-fixed coordinate system 293
Earth-fixed coordinate system 293
18 Inspection, test, and rebuild 299
Safety first 299
Test and rebuild 302
Costs 304
Health and safety and the environment 306
19 Sustainability 325
The three centric concerns of sustainability 325
Transforming our world: the 2030 agenda
for sustainable development 327
Discussion 328
Insurance 329
Contents ix
20 Brief history of motorcycles 331
Purpose and use 334
World war I 335
Between the wars 339
World war II 340
The golden era 340
1969 – The sea change 342
The millennium 344
Timeline 345
Appendix – Apprenticeship standard for
a motorcycle technician 351
Glossary 355
Index 359