First, the operating environment to dust, wind, the operation should be standardized
Some motorcycle repair shop overhaul engines are operated in the outdoors, they no matter how much dust, only for the bulkhead for parts. Jun do not know, dust mixed into the machine will cause undue abrasive wear, in this environment for the new oil may be dirty than the old oil, overhaul the engine must be indoors. In addition, the operation should be standardized, the demolition of the demolition, not to move not to move. Such as for CC125 variable cam and fork, the engine does not have to open the left box, crankshaft do not have to remove, you can change the speed change institutions. If the misuse will cause unnecessary trouble, not only work erroneous, there may be caused by side box sealing bad. Repair the engine is a prerequisite for its well aware, carefully comprehend the engine parts and components structure.
Second, the engine shell clean before the removal of essential
Overhaul of the engine when the shell has a lot of oil and dust accumulation, if not promptly cleaned, these impurities will be in the dismantling of the engine when mixed with the internal body, installed, the relevant parts to bring unnecessary wear and tear. Moreover, the foreign body into the engine, the change will plug the oil, and will result in poor lubrication, resulting in holding cylinder, hold shaft, clutch sintering. In addition, the engine housing without cleaning, in the box, the foreign body will be stuck in the box junction, affecting the seal, resulting in oil leakage, oil spills. Cleaning the engine casing, but also can prevent the sludge cover the bolt, so as not to leak removal. Such as the engine box in Chongqing 80 bolts, there are two extremely easily covered by sludge, if the leak demolition, forced devanning, will damage the engine box.
Third, it is important to mark well
Whether mature models, or transition models, motorcycles engine variety, structural characteristics vary. When we break down a variety of engines, should do a variety of accessories to install the mark, some nuts are the same thread, but the appearance of different, should mark well, not any installation, because all kinds of nuts have a certain torque requirements, Various shapes are determined after several tests, there is a certain scientific basis, if the swap, will affect its fixed effect, causing a new failure. Such as the CG125 clutch nut and crankshaft oil filter nut on the right end of the same thread, although the swap can be fitted, but the two different shapes, different torque, the clutch nut fixed torque than the cranknut nut is much greater. When we open the car is not familiar with the engine, such as CB125T, CBR400, etc., should be in the demolition of the pieces on the mark, to prevent the wrong equipment,
Fourth, the use of special tools, special containers
The use of tools directly affects the quality and efficiency of maintenance work. Special tools for the maintenance of the specified parts of the design, science and easy to use, effort, not to hurt the accessories, such as trouble, plans to save money, just take a tool for illegal operation will greatly reduce the quality of work. For example, after the demolition of GY6 machine clutch nut applied 19 # wrench and wrench with the wrench can be successfully removed, we can see some repair shop without special tools, just take the steel brutal demolition, the nut is removed, the shape of the nut How can the torque be tightened again? Clutch nut loose will cause the clutch assembly falling off, the consequences could be disastrous. There was a motorcycle Friends of the motorcycle overhaul soon after the clutch off the side box caused by rupture. Non-standard operation can also damage the bearings at the inner end of the output shaft.
In addition, when we open the engine, the parts before and after cleaning should be placed in order in a dedicated aluminum plate or wooden plate, can not be stacked anywhere, some very small parts easily lost, such as the crankshaft semicircle key , The piston pin Dang Quan, all kinds of Cyper gasket positioning pins, and so on.
Fifth, the accessories placed in order
Decomposition of the unfamiliar engine, according to the order of placing the parts to prevent leakage installed, wrong equipment. Such as the car engine shift gear, in the replacement of damaged parts, according to the decomposition from left to right one by one to gracefully, replace the new assembly in reverse order, so as to avoid errors.
6, the relevant parts of the clean-up is critical
Once the engine disassembled, the pads (paper, asbestos and other gaskets) will promote the use of elastic, to promote the role of sealing, can not be reused, should be completely eradicate the replacement of new products. In addition, the sealing area of ??the gasket should be carefully removed (DX100, AX100, K100 two-stroke engine in the box) with bamboo chip, and then evenly coated with genuine special sealed sealing box fastening. The demolition of the pieces and the parts with the gap of the sludge, grinding the application of bamboo completely removed, such as CG125 oil filter, C100 clutches in the hard debris. This work also determines the use of the engine after overhaul was ordered. Some maintenance workers just replace the damaged parts, do not replace the fatigue of the oil seal, gasket, circlip, do not clean the machine sludge, impurities, installed on the shelves, although the car can ride, but time is not long, the new failure will occur.
7, replacement parts should be carefully measured, compared
Accessories market cohabitation, in order to ensure the quality of maintenance, in the purchase of genuine but also the old pieces with the new pieces carefully compared with the actual use of special tools to measure the requirements of the engine after the overhaul intact. Such as the replacement of crankshaft, cylinder components and other parts, the use of vernier caliper measured whether the standard parts of the crankshaft, whether to meet the rigorous measurement of the cylinder ring, to avoid the equipment installed Bi test only found problems, time and time lost.
8, mechanical assembly of lubricating oil applied indispensable
Assembly of the demolition of the pieces to take the amount of new lubricants evenly applied to the various parts of the combination of parts, such as crankshaft and bearings, gear cam and box, gear and gears, between the cylinder ring and other pieces, cast lubricants Assembly will be more smooth, in order to facilitate the co-me tight, to avoid the assembly of the pieces of dry hair astringent, the box is difficult, resulting in damage to mechanical parts.
9, the choice of standard gaskets, caution with sealant
When the engine assembly, the selection of new gasket can not be ignored, if the choice of non-standard gasket, will result in oil spills, start-up difficulties (two-stroke car air leakage, resulting in mixed gas too thin, therefore difficult car) Even worse will result in blocked oil, causing a new failure. Especially on the cylinder pad, demanding, defective easily burn through, the use of asbestos can not use aluminum pad, too thick will also affect the compression ratio, causing the vehicle hard to start, driving weakness. In addition, we must pay attention to the gum gasket, sealing ring can not be leak fitted, such as CY80, DX100, AX100 crankshaft on the apron, carburetor interface apron. Sealant used in the assembly of the engine is very small, only in the two-stroke car in the box assembly, CB cylinder head will be used, four red car engine assembly generally do not have a drop of sealant coated, such as C100, CG125, CG150, GY6 The machine at the junction of the gasket, the apron can be sealed well. Coated with sealant is conducive to sealing, but the sealant will block the oil more, causing new problems. If there is a combination of apron coated with a sealant, will cause the apron was sticky
10, pay attention to replace the oil seal
Engine overhaul, after disassembly of the relevant oil seal, there will be different degrees of operation, should be properly replaced with new products to prevent oil leakage or mixture leakage, resulting in difficult to start. Individual large displacement motorcycles or special-shaped motorcycle oil seal to buy difficult, if the original car oil seal operation is not, you can remove the oil seal lip spring, cut about 5mm, can be used as usual.
11, replacement parts to be installed while debugging side
Replace the damaged parts to standardize the operation, proper installation, make debugging, take preventive measures. Such as the replacement of C100 start-up shaft, remove the shaft before the use of hacksaw on the box to do a good start gear position mark, installed after the completion of the new start-up shaft, to start the test box (not only to start smoothly, Position, start the gear and the gears do not hinder each other), and then tighten the fixing bolts, variable test variable transmission block changes whether the ease of clarity, oil pump shaft is installed in place to avoid a new failure.
12, good waterproof work
And the engine connected to the wiring harness to plug in place, do waterproof, rain work. After the engine is mounted on the large frame, the wiring harness should be straightened out and the plug can not be leaked to ensure the lighting charging line works normally. In addition, the waterproof cover should be installed firmly, wiring harness firmly, there is no waterproof cover the application of waterproof tape wrapped tight.
XIII, attention to the safety balance of air hole hose
Has seen a number of overhauled motorcycles, air balance hole hose leak installed, the course of time, the balance hole is blocked by foreign body, causing the engine internal temperature is too high, driving weakness, no high-speed phenomenon. In addition, the hose discount, stuck in the big frame, will also cause the phenomenon.
14, beware of two-stroke motorcycle oil pipe off or blocked by foreign bodies
After removing the engine, the oil pipe should be promptly plugged with a clean 6 # bolt to prevent dust and other foreign matter into. Install the engine, the oil pipe should be straightened out to prevent the stuck, both ends of the fixed with a circlip, beware of falling off after the new failure.
15, the engine and the big frame to connect the ground wire to install firmly
General electric start motorcycles, the engine and the big frame has a coarse between the wire, both ends must be on the real, to avoid virtual access, otherwise, will cause the motor to start working weak, difficult to start.
16, the engine fixed accessories can not leak
For example: the engine and the flexible combination of large steel frame sets of leakage of equipment, will cause the engine resonance, the driver felt very uncomfortable. , Or even cause traffic risk. Chongqing 80, Jetta 100, Jincheng 90, are the structure. In addition, the missing engine fixed bolts on the flat washers and spring washer, a long time, will cause the engine loose, affecting traffic safety.
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