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1. Valve Valve Upper Lower Initial Lash Installed New New Valve Score Number Type Lash Lash Measureme Shim Shim Lash 0 15 frt s Limit Limit nt Measureme Chose Measureme 25 1 4 nt n nt pts each rear Corrected s 5 Lash 8 1 7 Exhaust 345m 295 m m 2or8 Exhaust 345m 295 m m 5 Intake 245m 195m m m 4or6 Intake 245m 195m m m Total Number of Points _______ 0 15 25 30 45 50 65 75 80 95 100 Skills USA 2009 Motorcycle Service Technology Contest Workstation 1 Precision Measuring VRSC Valve Lash Adjustment amp Slipper Clutch Inspection Page 2 of 4 Using the Valve Lash Student Reference Guide briefly explain the purpose of the numbers and arrows that are associated with the camshaft journal caps The camshaft journals are line bored as an assembly prior to the final machining processes Each cap has a cast in numbered for its location and the cylinder head is casted with a corresponding numbers The cam journals are also casted with an arrow to indentify the direction that each journal should be installed The directional arrows will point to the cylinder head spark plug hole for proper installation Total Number of Points _______ 0 10 recorded assembled and torqued the cam journal caps a Specification 9 7 Nm 86 in Ibs _ Total Number of Points _______ 0 10 With a shim unde
2. Question 4 What reading is displayed Wy this micrometer Type your answer here HARLEY DAVIDSON UNIVERSITY 24 002 mm Question 5 What reading is displayed by this micrometer Type your answer here HARLEY DAVIDSON UNIVERSITY 48 mm 004 mm Question 6 What reading is display amp gd by this micrometer Type your answer here X HARLEY DAVIDSON UNIVERSITY Measure all 4 Valve Shims and record your measurement on your worksheet 57101756 HARLEY DAVIDSON UNIVERSITY Record your Measurements on Worksheet 2009 HARLEY DAVIDSON SKILLS USA COMPETITION VALVE LASH WORKSHEET Record your shim measurements in the column below Current State Corrected State VRSC Front Cylinder REMEMBER TO ALWAYS VARY TO THE SIDE OF THE UPPER LIMIT OF THE VALVE LASH RANGE SLASH TENDS TO GO LOWER AS THE MILEAGE ON THE MOTORCYLE INCREASES With a shim under bucket design to increase valve lash does a technician need to find a smaller or larger shim With a shim under bucket design to decrease valve lash does a technician need to find a smaller or larger shim HARLEY DAVIDSON UNIVERSITY Record your Measurements on Worksheet 2009 HARLEY DAVIDSON SKILLS USA COMPETITION VALVE LASH WORKSHEET Record the NEW shim size that you have VRSC Front Cylinder selected in the column below Current State orrected State
3. 9 MOTORCYCLE MECHANICS INSTITUTE A DIVISION OF UNIVERSAL TECHNICAL INSTITUTE Skills USA 2009 Motorcycle Service Technology Contest Written Test Motorcycle Technology Theory KEY KEY KEY KEY KEY KEY KEY 1 1 2 ____ 198 ____ 2 _____ ni _____ 20 ____ ____ Co 5 21 ____ _____ E ____ 22 ____ _ ____ _____ 23 du an 24 ____ ____ Ben MN 25 ____ ____ _____ 26 ____ _____ 10 ____ _____ 27 ____ ____ _ 29 D ___ 12 29 A __ 30 D 14 31 __ 15 B 32 C 16 B 33 D Skills USA 2009 Motorcycle Service Technology Contest Written Test Answer Sheet Motorcycle Technology Theory Sponsored by MOTORCYCLE MECHANICS INSTITUTE A DIVISION OF UNIVERSAL TECHNICAL INSTITUTE Skills USA 2009 Motorcycle Service Technology Contest Written Test Motorcycle Technology Theory CONTESTANT 11 12 13 21 22 23 27 28 29 31 32 33
4. Next click on the E and record fuel H E pressure from the ise data screen on your answer Pe sheet gt as iea 1 7 4MZHL04D683800037 CONGRADULATIONS have completed this work station test Please hand your worksheet to your judge and organize your work area for the next contestant Skills USA 2009 Motorcycle Service Technology Contest Written Test Answer Sheet Buell P3 Blast Service Manual Sponsored by MOTORCYCLE MECHANICS INSTITUTE A DIVISION OF UNIVERSAL TECHNICAL INSTITUTE SkillsUSA 2009 Motorcycle Service Technology Contest Written Test Key Buell P3 Blast Service Manual Sponsored by lt MOTORC YCLE MECHANICS INSTITUTE A DIVISION OF UNIVERSAL TECHNICAL INSTITUTE N Ul 10 11 12 13 14 15 16 17 18 19 20 gt gt gt O gt O gt u gt Skills USA 2009 Motorcycle Service Technology Contest Written Test Key Buell P3 Blast Service Manual 10 11 12 13 14 15 16 17 18 19 20 Skills USA 2009 Motorcycle Service Technology Contest Written Test P3 Blast Service Manual CONTESTANT SkillsUSA 2009 Motorcycle Service Technology Contest Written Test Answers Buell P3 Blast Service Manual Sponsored by m P MO
5. 0 3 6 7b Identified that the air fuel ratio would be richer at higher altitude 0 3 6 Identified the float bowl hole as for the choke circuit 0 3 6 8b Identified that the choke wouldn t work if the hole is plugged ____ 0 3 6 9 Carburetor correctly reassembled ____ 0 3 6 10 Materials put in their ____ 0 3 6 JOB SKILLS Used tools safely and properly 0 3 6 Cleaned organized the work area 0 3 6 TOTAL POSSIBLE SCORE 150 correct places 2009 Skills USA Championships Motorcycle Service Technology Contest Workstation 4 Buell Dynamic Digital Fuel Injection Component Identification and Function Sponsored by Buell Motorcycle Company Skills USA 2009 Motorcycle Service Technology Contest Workstation 4 Buell DDFI Component 1 0 6 Function Objective Information Sheet Time Limit 30 Minutes OBJECTIVE Given a Buell Dynamic Digital Fuel Injection DDFI simulator board and Buell Service Manual participants will correctly identify the system components and function as listed and described in the service manual SPECIFIC SKILLS The contestant will 1 Locate the components in the service manual 2 Correctly identify the components on the simulator board 3 Correctly answer the questions pertaining to the components on the worksheet 4 Clean and reorganize the work area Skills USA 2009 Mo
6. ECM Engne Speed 0 5 Idie Aur ECM ntrol Live ECM a 21 21 1 Data Items Data Items Next Click on the circled Active Diagnostics Icon ot idie Source Module Description Value Units Hot idis Limit Min Max Status X Battery Voage pus ves me me Engine Coolant Temperature Intake Air Temperature Sensor m RN Absolute Pressure Sensor he we Throttle Position 1 Throttle Position Throttle Position Senso Idie Control Steps n 14 Click on the circled Fuel Pump ECM Icon Test is not running Then click on the Star butto 4MZHL04D683B00037 8 Active Diagnostics Even with the engine turned off hot engine can still create a dangerous condition if fuel makes contact with a hot surface Next read the warning and then click on the circled Proceed button The fuel pump will activate for 30 seconds to reestablish system fuel pressure 16 The top screen is what you will see 4 nn while the pump is activated Allow the pump to complete its 30 sec test 4 MZ EHLOIDE 69299097 EN FALE YE 903
7. The larger diameter steel plate is installed after a unique narrow spaced friction plate on the pressure plate side Total Number of Points _______ 0 10 Combined Total Possible Score for VRSC Slipper Clutch 150 Contestant Total Score for VRSC Slipper Clutch Combined Total Possible Score for VRSC Valve Lash amp Slipper Clutch Inspection 300 Contestant Total Score for VRSC Valve Lash amp Slipper Clutch Inspection 2009 Harley Davidson SKILLS USA Competition VRSC Slipper Clutch Worksheet Contestant VRSC Slipper Clutch Disassembly Inspection and Re assembly Instructions Follow the applicable Student Reference Guide and the outlined procedures to correctly disassemble inspect measure and re assemble a VRSC clutch assembly Areas of Inspection Clutch Spring Free Length Factory Spec mm Clutch Friction Plates Factory Spec mm Steel Plates Warpage Factory Spec mm Measurements Instructions Comments Results 3 62mm HARLEY DAVIDSON UNIVERSITY EIN 55 2 E m 4 Harley Davidson Slipper Clutch Workstation Student ence Guide AU 2 x D Me ir 4 a we gt P TVA 15 4 X EQ S lt lt e 2 5 a E t x VRSC Clutch Component Identification e 7 Clutch Hub 8
8. 6 using the following criteria indicates that the contestant could not perform this skill 3 indicates that the contestant could partially perform this skill 6 indicates that the contestant could perform the skill PERFORMANCE 1a Student identified the main jet size 0 3 6 1b Student identified it as correct main jet 0 3 6 1c Student identified main 5 main effect 0 3 6 2a Student identified pilot jet size 0 3 6 2b Identified correct size for this carb 0 3 6 2 Identified emulsion holes and rich condition 0 3 6 3a Correctly measured float height 0 3 6 3b determined it is correct height 0 3 6 3c Identified that would run overflow 0 3 6 4a Identified slide cutaway number 0 3 6 4b Identified stock cutaway number for this model 0 3 6 4c Identified that a higher cutaway number leans the fuel mixture 0 3 6 5 Identified the needle currently in the carb 0 3 6 5b Identified the correct needle size for this carb 0 3 6 5 Identified correct clip position 0 3 6 Identified correct standard screw position 0 3 6 Identified that mixture is leaner with turns out 0 3 6 7a Identified that a smaller main jet would be used at altitude
9. Carburetor Inspection Instructions to Judge Set Up 1 Verify that the carburetor is ready for the contestant 2 Confirm that the prior contestant hasn t changed any settings Inventory per Workstation Four workstations Qty Description Part Number Furnished By 1 Yamaha PW80 Motorcycle carburetor Yamaha 1 Number 2 phillips screwdriver Snap on 1 PW80 Service Manual Yamaha 1 Metric calibrated small ruler Snap on 1 Small flat blade screwdriver Snap on 2009 SkillsUSA Championships Motorcycle Service Technology Contest Workstation 3 Carburetor Inspection Contestant Worksheet Contestant _________ On the table is a carburetor assembly for a Yamaha PW80 dirtbike You will be asked to inspect this carburetor and answer questions about its function Remove the float bowl from the assembly Identify the main jet What size main jet does BET AN On en ar et nF rm en 2c As you look at the pilot jet there are eight small holes in the jet body If these holes were plugged what effect would there be on the air fuel ratio 3a Identify the float assembly and measure the float height What height do you find 3b 15 this the correct height 3c If the float height was set at 10mm what effect would this have on carburetor operation 4c If the slide cutaway number is a higher number than stock what effect would this have on air fuel ratio 2009 SkillsUSA Championships Motorc
10. 05 VDC SkillsUSA 2009 Motorcycle Service Technology Contest Written Test Buell P3 Blast Service Manual Sponsored by M AOTORC YCLE MECHANICS INSTITUTE A DIVISION OF UNIVERSAL TECHNICAL INSTITUTE SkillsUSA 2009 Motorcycle Service Technology Contest Buell P3 Blast Service Manual Objective This written test allows the participant to demonstrate knowledge of Buell Blast Motorcycle and the ability to locate specific information contained in the manual provided Directions Reference the provided 2002 BUELL P3 BLAST FACTORY SERVICE MANUAL PN 99492 02Y for all test questions Select the best answer s for each question and then fill in the appropriate letter s box on the answer sheet provided 1 The front wheel bearings should be inspected _________ every 10 000 miles when the rear wheel is removed when the front wheel is removed only when a grinding noise is heard 2 The brake fluid should be replaced every Choose 2 answers A ATF B DOT 5 C DOT 4 year 2 years 4 years 3 What color is the wire that provides current to the ignition switch A Red R B Yellow Red Y R C Brown Yellow BN Y D Gray GY 4 The fuel valve is in the reserve setting when the arrow is pointing 20 A right rear B left front C up D down Page 1 of 4 5 The capacity of the fuel tank is 3 0 gallons A True B False 6 __________ is th
11. Steel Plate 7 9 Pressure Plate e 10 Clutch Springs 11 Lifter Plate Fasteners 14 Lifter Plate 15 Damper Spring Seat 16 Damper Spring 17 Narrow spaced friction plate 2 19 Wide spaced friction plate 7 26 Large Inside Diameter Steel Plate 1 HARLEY DAVIDSON UNIVERSITY VRSC Clutch Disassembly Remove lifter plate fasteners using a crisscross pattern HARLEY DAVIDSON UNIVERSITY HARLEY DAVIDSON UNIVERSITY Han gt 29 a rtm nr Metric Dial Caliper Reading e The following pages are provided as a review section of the key points for using a Metric Dial Caliper e If you are confident and comfortable using a Metric Dial Caliper proceed to page 22 and begin HARLEY DAVIDSON UNIVERSITY HARLEY DAVIDSON UNIVERSITY Using a Dial Caliper The Dial Caliper is a convenient measuring instrument for making outside inside and depth measurements HARLEY DAVIDSON UNIVERSITY Reading Metric Dial Cal per Keep in Mind that the Metric system 15 built on a base 10 foundation Each graduation on the main scale represents whole millimeter or Imm Written as 1 00mm HARLEY DAVIDSON UNIVERSITY AMERICAN ag HARLEY DAVIDSON UNIVERSITY Sta AMERICA 8 HARLEY DAVIDSON UNIVERSITY AMERICAN 8 HARLEY DAV
12. A is both 20 weight and 50 weight oil combined C is a 20 weight mixed with 30 weight D thins less when cold than a 20 weight and thickens less when hot than a 50 weight 19 The component found in the oil filter that allows oil to flow if the filter becomes clogged is the A oil pressure relief valve C reed valve D oil pump 20 The bearing which is the best for radial loads but not at all good for axial loads is the A thrust bearing B tapered roller bearing C ball bearing 21 Which one of these is one of the four purposes of bearings B lubricate C impressibility D permeability 22 In a liquid cooling system the thermostat B determines the cooling system s operating pressure C is a heat exchanger D sends electrical data to the instrument panel 4016 23 In liquid cooling system the determines the cooling system s operating pressure 24 25 26 27 28 thermostat water pump C radiator Octane is the fuel s ability to A increase mechanical efficiency B resist chemical breakdown D increase stroke efficiency The main purpose of oxygenated fuels is to A improve fuel mileage of the engine B reduce CO2 emissions D reduce HC emissions Air density B decreases as altitude decreases C affects the pressure differences D increases and altitude increases An air fuel ratio of 12 1 has A 12 parts air by volume to
13. the upper left hand icon Vehicle Select Pausing the cursor arrow over any button icon will cause a brief description of that button to pop up No Vehicle Selected DIGITAL 2 p Vehicle Information Techi Carefully type in the VIN 02777777777777777 Please enter vehicle Vehicle Identification number VIN Family The VIN is located T on the forward right side of the frame right behind Odometer the steering neck NOTE All Os in the VIN are numbers not letters Region Miles No Vehicle Selected 1 Customer Information Use the provided flashlight if necessary to read the VIN Click in the rci ed Vehicle Information Techlink Selection Q D Q M ET E R X 4MZHL04DX33B00056 Ploase enfer vehicie odometer reading and enter the 2008 Make vehicle mileage displayed on the gt motorcycle em n st ru m nt United States Model cluster Next click on the circled check box Vehicle Info JENEM 8 elo ZHLO4DXS3B00056 Please Select a vehicle Customer Information Click the circled TT TOOLBOX icon United States Model 4MZHLO4DX83B00056 GEB DE This is the screen you will see It lists any current or historic fault codes for the vehicle Record thes
14. 0 3 10 16 ________ 17 Fuel Pressure after disconnecting fuel pump connecter and cranking starter 5 0 3 10 17 ________ 18 Fuel Pressure after reconnecting fuel pump connector and energizing pump 73 74 PSI 0 3 10 18 ________ 19 Properly cleaned their work area and shut off the ignition switch 0 3 10 19 Ze 20 Properly disconnected fuel pump connector with no potential damage 0 3 10 20 ________ Total Possible Score 200 Total Points Buell 11258 Engine Diagnostics AND FOLLOW THESE INSTRUCTIONS CAREFULLY AND DON T MISS STEP THERE IS A COMPUTER GLITCH NOTIFY YOUR JUDGE AND HE OR SHE WILL CORRECT IT AND IF NECESSARY ADD APPROPRIATE TIME AT THE END OF YOUR SESSION ATHESE COMPUTER SCREENS ARE TOUCH SENSITIVE AND THE SUPPLIED TOUCH PEN CAN BE USED FOR SELECTING ICONS RATHER THAN THE MOUSE PAD AND BUTTONS IT S YOUR CHOICE Buell 11258 Engine Diagnostics XWelcome to the Digital Technician Il motorcycle diagnostics tool Follow these directions carefully and you will be rewarded with an enjoyable and informative sample of motorcycle computer aided diagnostics AN our first step is to select the RUN position of the motorcycle Run Stop switch and then turn the ignition key to the ON position to establish communication between the motorcycle and the Digital Technician computer From the wen Digital DT home screen select single click or tap
15. A 22 25 ft Ibs Pg 2 3 2 54 22 52 ft lbs C 100 in Ibs D Good and tight 7 The lateral runout of the front tire should not exceed A 8 000 B 2 030 C 0 800 D 0 080 Pg 2 18 E none of the above 8 The spark plug cable should have a resistance of ohms A 0 00 B 2 375 5 833 C 2 375 5 833 Pg 7 25 D infinity 9 The Pink PK wire at the ignitions coil connector 83B goes directly to the ignition module A True Pg 7 24 B False 10 ignition coil pn Cis A 12 VDC B ground Pg 7 24 C the front cylinder s primary coil trigger D the rear cylinder s primary coil trigger Page 2 of 4 Ref Ignition Test 2 Neutral Switch Function Fig 7 31 Pg 7 27 for the next 3 questions 11 The vehicle set up or Condition for the test A sidestand up key ON transmission in neutral and clutch engaged B sidestand up key ON transmission in neutral and clutch disengaged C sidestand down key OFF transmission in neutral and clutch engaged D sidestand down key ON transmission in neutral and clutch engaged Pg 7 27 12 If the Voltage is found to be Battery Voltage minus 2 volts at the Diode 2 TN Y and the youshoud A check for continuity between TN Y and Diode 2 B check for ground at TN on Diode 1 Pg 7 27 C repair wiring D tell the customer that no faults were found 13 If the ground is not present at TN on Diode 1 yu shoud 0 A
16. REMEMBER TO ALWAYS VARY SIDE OF THE UPPER LIMIT OF THE VALVE LASH RANGE A SLASH TENDS TO GO LOWER AS THE MILEAGE ON THE MOTORCYLE INCREASES With a shim under bucket design to increase valve lash does a technician need to find a smaller or larger shim With a shim under bucket design to decrease valve lash does a technician need to find a smaller or larger shim HARLEY DAVIDSON UNIVERSITY 57101757 HARLEY DAVIDSON UNIVERSITY Re nstall Camshafts and Journal Caps noting their locat on numbers and directional arrows Fr sm04768 HARLEY DAVIDSON UNIVERSITY 2009 Skills USA Championships Motorcycle Service Technology Contest Workstation 2 Electrical Troubleshooting Sponsored by Yamaha Motor Corporation 2009 Skills USA Championships Motorcycle Service Technology Contest Workstation 2 Electrical Troubleshooting Objective Information Sheet Time Limit 30 Minutes OBJECTIVE This workstation will enable the participant to demonstrate specific skills related to electrical circuit troubleshooting using a digital multimeter on motorcycle SPECIFIC SKILLS The contestant will 1 Properly use a service manual to identify electrical circuits components and find resistance specifications 2 Properly measure voltage and resistance 3 Evaluate the results of electrical tests to determine the cause of a failure 4 Use the tools and equipment properly and safely Clean
17. This is what you should see 1 Next attach the supplied multimeter leads to the meter and to the motorcycle battery terminals pe Turn the meter dial Mode imits to the appropriate lecti 0 record the existing 0 0000 0 0000 batte ry voltage Reset Reset 4MZHLO4DX83B00056 Carefully lift the locking tab on the fuel pump connector and disconnect the four wire connection to disable the fuel pump as will damage the connector 11 Select or touch both buttons in the Min and Max screens With fuel pump disconnected press the STARTER button and crank the engine over for about 5 seconds The engine may pop over a few times but will not start Record the battery Min and Max values Ignore the values you see on this printed page Disconnect the voltmeter when finished 12 SY A Display Mode mj 0 0000 0 0000 Reset Reset Return to the DATA ITEMS screen by selecting the DATA ITEMS icon on the left edge of the screen From the Value and Units column record the current fuel pressure Reconnect the fuel pressure connector 13 2 2 Osto rm Meters Graph Data Items Clear Hot Idle Hot Idle Limit 5 U ource Module Dascnption Value Units Mn Max Status
18. punch out and go home early B check for ground at the neutral switch terminal Pg 4 60 C check Diode 1 with an ohmmeter D replace the Diode 14 The m circled 4 in the flow chart instructions on page 7 65 indicates that A the seat should be removed Pg 7 63 B order in which the tests are to be done C a continuation point from another test flow chart D the test needs to be done 4 times 15 Terminal 8 of the Instrument Connector 20 Ss__________ A a Black BK wire B aRed R wire C a Green Yellow GN Y wire D not used Pg 7 67 16 The specified torque for the lifter anti rotation screws 15 _________ 3 5 Nm 15 19 ft Ibs 80 110 in 105 55 65 in 105 Pg 3 4 3 54 none of the above gt 3 014 17 The Speedometer Diagnostic code indicating power over voltage 15 __________ 1 8 7 59 CAL 14 910 18 When performing the Speedometer Performance Check with the Speedometer Tester HD 41354 a frequency of 1803 Hz should reflect a speedometer display of MPH on a USA market meter A 20 B 40 60 7 62 80 19 The exhaust push is identified __________ colored band A Black Pg 3 33 B White C Pink D Orange 20 The Throttle Position Sensor TP Voltage is checked with the throttle plate fully closed and should have a reading of A 45 55 VDC Pg 4 26 B 45 55 ohms C 5 5 VDC 5
19. your worksheets and pencil with the judge Skills USA 2009 Motorcycle Service Technology Contest Workstation 1 Precision Measuring VRSC Valve Lash Adjustment amp Slipper Clutch Inspection Judge s Score sheet Page 1 of 4 Start Time Stop Time Scoring Directions Use the scoring criteria outlined below indicates the contestant could not perform this skill 10 or 25 indicate that the contestant cou d perform the skill or correctly answered the question and was awarded the total score 15 indicates that the contestant could partially perform the skill for the Valve Lash Adjustment PERFORMANCE VRSC VALVE LASH ADJUSTMENT 150 PTS 1 Accurately identified the two 2 positions necessary to establish the camsahft base circle prior to measuring the valave lash Total Number of Points _______ 0 10 2 Accurately measured and recorded Valve Lash Valve Shims and made appropriate changes to valve lash components Compare student measurements in all recorded columns to factory specifications listed in the table Place a check mark 4 in the appropriate space to indicate a good measurement was obtained towards the higher end of the specification and the full score amount of 25 Or place a check minus 4 to indicate a measurement that is narrowly out of specification allocating a partial score amount of 15 Or place an X in the space to indicate an inaccurate measurement and a zero score
20. 09 HARLEY DAVIDSON SKILLS USA COMPETITION VALVE LASH WORKSHEET Record your Final Valve Lash Measurement here Current State Corrected State VRSC Front Cylinder REMEMBER ALWAYS VARY TO THE SIDE OF THE UPPER LIMIT OF THE VALVE LASH RANGE SLASHTENDSTOGO LOWER AS THE MILEAGE ON THE MOTORCYLE INCREASES With a shim under bucket design to increase valve lash does a technician need to find a smaller or larger shim With a shim under bucket design to decrease valve lash does a technician need to find a smaller or larger shim HARLEY DAVIDSON UNIVERSITY 2009 SkillsUSA Championships Motorcycle Service Technology Contest Workstation 3 Carburetor Inspection Sponsored by Yamaha Motor Corporation 2009 SkillsUSA Championships Motorcycle Service Technology Contest Workstation 3 Carburetor Inspection Objective Information Sheet Time Limit 30 Minutes OBJECTIVE This workstation will enable the participant to demonstrate specific skills related to carburetor disassembly and inspection SPECIFIC SKILLS The contestant will 1 Properly find the service manual section on carburetor circuits components 2 Properly identify carburetor circuits components 3 Properly determine correct carburetor components and adjustments 4 Use the tools and equipment properly and safely 5 Clean and reorganize the work area 2009 Skills USA Championships Motorcycle Service Technology Contest Workstation 3
21. 1 part fuel B 1 part air by volume to 12 parts fuel D 12 parts fuel by weight to 1 part air The force that results from an electrical pressure difference is called 50f6 29 Which of the following formulas is correct B Volts X Ohms Amps C Ohms Amps Volts D Amps Volts 5 30 The two major types of charging systems A rising field collapsing field B excited field normally open C permanent magnet full wave 31 The three strengths of charging systems are A half wave full wave permanent magnet B half wave full wave sine wave D permanent magnet electromagnet rising field 32 The ignition coil s winding windings has more wire turns than it s A solenoid starter B field stator D primary secondary 33 An ignition coil operates on the principle of A polarity B grounding C residual magnetism Skills USA 2009 Motorcycle Service Technology Contest Written Test Motorcycle Technology Theory Sponsored by X cp MOTORCYCLE MECHANICS INSTITUTE A DIVISION OF UNIVERSAL TECHNICAL INSTITUTE SkillsUSA 2009 Motorcycle Service Technology Contest Motorcycle Technology Theory Objective This written test allows the participant to demonstrate knowledge of Motorcycle Technology Theory Directions Select the best answer s for each question and then fill in the appropriate letter s box on the answer sheet provided 1 Using the following informat
22. 5mm 0 15mm 0 15mm 0 15mm 0 15mm 0 15mm Total Number of Points _______ 0 15 25 30 45 50 65 75 2 The damper spring is installed onto the damper spring seat with the concave side _Up Total Number of Points _______ 0 10 3 There are two unique Friction Discs How are these installed in relationship to the other friction discs The two unique friction plates are installed as the first and last plate among the other clutch plates within the entire clutch Total Number of Points _______ 0 10 4 In which direction should the steel plates be installed The steel plates should be installed with the rounded side towards the direction for clutch disengagement i e in towards the clutch basket Total Number of Points _______ 0 10 5 Per your answer above why should the steel plates be installed this way Installing the steel plates with the rounded side facing the direction of disengagement helps improve clutch disengagement The opposing side of the steel plate has a sharp edge due to the manufacturing process of stamping the Skills USA 2009 Motorcycle Service Technology Contest Workstation 1 Precision Measuring VRSC Valve Lash Adjustment amp Slipper Clutch Inspection plates This edge could cause drag or added resistance when disengaging the clutch Total Number of Points _______ 0 10 Page 4 of 4 Describe where the larger inside diameter steel plate is installed within the clutch assembly
23. ABDC opens at BBDC and closes at ATDC 10 A two stroke engine with a leaking wet clutch side seal will exhibit which symptom A B C D run lean Smoke excessively none of the above allof the above Page 2 of 6 11 Changing a 32 1 pre mix ration to 50 1 will A put more oil in the fuel oil mixture B put less oil in the fuel oil mixture C lubricate the engine better D have no effect 12 Overdrive is a gear that is numerically A less than 1 1 B more than 1 1 1 1 none of the above 13 If the transmission output sprocket has 14 teeth and the rear wheel sprocket has 44 teeth what would the final drive ratio be A 3 143 1 B 2 333 1 318 1 D 40 000 1 14 Clutch drag is A the clutch does not transfer 100 of the engine s powerflow B clutch friction plates contaminated with oil C the clutch will not fully disengage D a clutch with worn out clutch springs 15 The largest driven gear found in a 5 speed indirect drive transmission will be A C5 B 1 M5 1 16 The four purposes of motor oil are A clean cool seal quiet clean cool seal lubricate C clean cool seal motivate D clean cool seal calcify Page 3 of 6 17 _________ is a lubricating system that stores oil in a remote tank A wet sump B centrifugal C splash D dry sump 18 a 20W 50 multi viscosity motor oil is one which A is both 20 weight and 50 weigh
24. HG 10 Throttle Position Degrees at Closed Throttle ___________ 11 Throttle Position Degrees at Wide Open Throttle 12 Clutch Switch Input w clutch lever out 13 Clutch Switch Input w clutch lever compressed to handlebar 14 From page 10 in Test Booklet Existing Battery Voltage 15 Minimum Battery Voltage after cranking starter motor for 5 Seconds 16 Maximum Battery Voltage after cranking starter motor for 5 Seconds 17 Fuel Pressure after disconnecting fuel pump connecter and cranking starter motor STOP Leave this worksheet and pencil with the judge SkillsUSA 2009 Motorcycle Service Technology Contest Workstation 5 Digital Technician Diagnostics Organize your work area to prepare for the next contestant SkillsUSA 2009 Motorcycle Service Technology Contest Workstation 5 Digital Technician Diagnostics Judge s Scoresheet Contestant Judge s Initials __________ Scoring Directions Unless otherwise specified the performance of each skill should be 0 3 or 10 using the following criteria indicates the contestant could not or did not perform this skill Nothing has been recorded for that answer or an incorrect value such as Throttle Position Percent rather than the requested Degrees 3 is awarded if the value is generally correct but a decimal point may be in the wrong spot 10 indicates the contestant could perform this skill PERFORMA
25. IDSON UNIVERSITY Starker AMERICAN 8 HARLEY DAVIDSON UNIVERSITY HARLEY DAVIDSON UNIVERSITY Reading Metric Dial 3rd read 1 100 graduations on the Dial These graduations must be added together if the needle s position is further than 1 graduation from 1 10 number 2 100ths is visible on the dial face Written as 0 02mm Starker AMERICAN HARLEY DAVIDSON UNIVERSITY 13 00mm 00 04mm HARLEY DAVIDSON UNIVERSITY 43 1 AMERICAN MADE 26 00mm 00 08mm HARLEY DAVIDSON UNIVERSITY 26 00mm 00 04mm HARLEY DAVIDSON UNIVERSITY RICAN MADE 292 lt P 00 08mm HARLEY DAVIDSON UNIVERSITY 42 00mm 00 08mm HARLEY DAVIDSON UNIVERSITY Clutch Component Inspection Record all your measurements on the worksheet provided Measure the Clutch Spring Free Length Measure the thickness of the clutch friction plates Inspect the clutch steel plates for warpage Compare your measurements to the factory specifications listed on your worksheet to determine the overall condition of the clutch componenis HARLEY DAVIDSON UNIVERSITY Clutch Re Assembly Component Identification Assembly Notes Important Component Identification Assembly Notes e 3 Unique clutch plates are utilized in the VRSC Slipper Clutch design e 2 friction p
26. NCE Using the instruction booklet record the following data below POINTS 1 Entered VIN correctly 2 0 3 10 1 2 Vehicle mileage entered correctly 0 3 10 2 ________ 3 Active and or Historic Code Numbers 110 possibly 628 87 0 310 3 1 4 Idle Air Control Steps Approx 144___________ 0 3 10 4 zone 5 Fuel Pressure 73 74 64 2 0 3 10 9 f 6 Battery Voltage _11 9 12 5 0 3 10 6 _______ 7 Engine Coolant Temperature _Ambient Temperature_ 0 3 T0 7 zen 8 Intake Air Temperature Sensor Degrees Ambient Temperature 0 3 10 8 ________ 9 Barometric Pressure HG Approx 28 5 In HG current reading from data screen 0 3 10 9 22er 10 Throttle Position Degrees at Closed Throttle _Approx 2 2 Degrees 0 3 10 10 ____ 11 Throttle Position Degrees at Wide Open Throttle _Approx 85 Degrees 0 3 10 11 12 Clutch Switch Input w clutch lever out __Released_ 0 10 12 ________ SkillsUSA 2009 Motorcycle Service Technology Contest Workstation 5 Digital Technician Diagnostics 13 Clutch Switch Input w clutch lever compressed to handlebar Pulled In 0 10 1052 14 Existing Battery Voltage __11 9 12 5 0 3 10 14 ______ 15 Min Bat V after cranking starter motor 5 sec _Approx 9 5 10 8 V 0 3 10 15 ________ 16 Max Bat V after cranking starter motor for 5 sec Approx Bat V
27. RLEY DAVIDSON SKILLS USA COMPETITION VALVE LASH WORKSHEET Record your valve lash measurements in this column Current State Corrected State VRSC Front Cylinder REMEMBER TO ALWAYS VARY TO THE SIDE OF THE UPPER LIMIT OF THE VALVE LASH RANGE SLASH TENDSTOGO LOWER AS THE MILEAGE ON THE MOTORCYLE INCREASES With a shim under bucket design to increase valve lash does a technician need to find a smaller or larger shim With a shim under bucket design to decrease valve lash does a technician need to find a smaller or larger shim HARLEY DAVIDSON UNIVERSITY HARLEY DAVIDSON UNIVERSITY Remove all 4 Cam Journal Caps Cam Journal gt Bolts 2 P mu y C gt gt v 1 vs c NT P TP gt 3 2 0 S 2 A 4 6 HARLEY DAVIDSON UNIVERSITY HARLEY DAVIDSON UNIVERSITY Removing Shim from Valve Collar sm01757 E j 22 2 5 Valve Shim Bucket HARLEY DAVIDSON UNIVERSITY Shim and Bucket removed 57101755 Bueket sa FI HARLEY DAVIDSON UNIVERSITY Metric Measuring Review 57101756 Barrel Thimble HARLEY DAVIDSON UNIVERSITY Metric Micrometer Set up and Reading 57101756 Thimble lock HARLEY DAVIDSON UNIVERSITY 50 75mm Mic Shown HARLEY DAVIDSON UNIVERSITY HARLEY DA
28. Skills USA 2009 Contest Projects Motorcycle Service Technology Click the Print this Section button above to automatically print the specifications for this contest Make sure your printer is turned on before pressing the button 2009 HARLEY DAVIDSON SKILLS USA COMPETITION VALVE LASH WORKSHEET Contestant VRSC Front amp Rear Cylinder Current State Corrected State Valve Number Valve Upper Lower Lash Initial Lash Installed Shim New Shim New Valve Lash frt s 1 4 Lash Limit Limit Measurement Measurement Chosen Measurement rear s 5 8 Corrected Lash 1or7 Exhaust 345mm 295mm 2 Exhaust 345mm 295mm 3or5 Intake 245mm 195mm 4or6 Intake 245mm 195mm REMEMBER TO ALWAYS TARGET THE UPPER LIMIT OF THE VALVE LASH RANGE AS VALVE LASH TENDS TO DECREASE AS THE MILEAGE ON THE MOTORCYLE INCREASES Contestant Number JUDGE SCORE 2009 Skills USA Championships Motorcycle Service Technology Contest Workstation 1 Precision Measuring VRSC Valve Lash Adjustment amp VRSC Slipper Clutch Inspection Sponsored by Harley Davidson Motor Company Skills USA 2009 Motorcycle Service Technology Contest Workstation 1 Precision Measuring VRSC Valve Lash Adjustment amp Slipper Clutch Inspection Objective Information Sheet Time Limit 2 Hours OBJECTIVE Given the tools various engine components workstation reference materials part
29. TORC YCLE MECHANICS INSTITUTE A DIVISION OF UNIVERSAL TECHNICAL INSTITUTE Skills USA 2009 Motorcycle Service Technology Contest Written Test Answers Buell P3 Blast Service Manual Objective This written test allows the participant to demonstrate knowledge of Buell P3 Blast motorcycle and the ability to locate specific information contained in the manual provided Directions Reference the provided 2002 BUELL P3 BLAST FACTORY SERVICE MANUAL PN 99492 02Y for all test questions Select the best answer s for each question and then fill in the appropriate letter s box on the answer sheet provided 1 The front wheel bearings should be inspected _________ A every 10 000 miles B when the rear wheel is removed C when the front wheel is removed pg 1 5 D only when a grinding noise is heard 2 __________ fluid should replaced every Choose 2 answers ATF DOT 5 DOT 4 year 2 years 4 97 and B 15 4 years mg 3 What color is the wire that provides current to the ignition switch A Red R B Yellow Red Y R C Brown Yellow BN Y D Gray GY Pg B 12 4 The fuel valve is in the reserve setting when the arrow is pointing A right rear Pg 1 33 B left front C up D down Page 1 of 4 5 The capacity of the fuel tank is 3 0 gallons A True B False Pg 2 1 Oman oe is the proper torque specification for the rear muffler strap bolts
30. VIDSON UNIVERSITY HARLEY DAVIDSON UNIVERSITY Reading Metric Micrometer Each graduation resent 001 millimeters or 1 1000 of a millim Vernier Scale HARLEY DAVIDSON UNIVERSITY 13 mm 000 mm What reading is displayed micrometer Type your answer here HARLEY DAVIDSON UNIVERSITY Summary Review Practice Example HARLEY DAVIDSON UNIVERSITY 9 graduations that gre gt 4 000 mm HARLEY DAVIDSON UNIVERSITY HARLEY DAVIDSON UNIVERSITY Metric Micrometer reading Summary Review Practice Example Read the vernier scale The line represented by the 6 is lined up perfectly The reading will now include 006 mm This will be the final digit of the measurement This is a 50 75mm micrometer This micrometer is showing 54 43 mm HARLEY DAVIDSON UNIVERSITY Metric Micrometer reading Summary Review Practice Example The Final Reading Each incremental reading is added together for the final reading The micrometer reading 15 4 000 43 006 4 436 mm HARLEY DAVIDSON UNIVERSITY 26 007 What reading is displayed byWhis micrometer Type your answer here HARLEY DAVIDSON UNIVERSITY 47 mm 002 What reading is displayed Py this micrometer Type your answer here HARLEY DAVIDSON UNIVERSITY 37 mm 006
31. and reorganize the work area 2009 Skills USA Championships Motorcycle Service Technology Contest Workstation 2 Electrical Troubleshooting Instructions to Judge Set Up 1 Verify that the multimeter is in proper working order 2 Confirm that the motorcycle s battery is fully charged Check its voltage before the contestant begins 3 Confirm all components wiring are properly connected prior to each contestant Inventory per Workstation Four workstations Qty Description Part Number Furnished By 1 Yamaha WR250X Motorcycle Yamaha 1 Snap On digital multimeter MT145 Snap On 1 WR250X Service Manual Yamaha 2009 Skills USA Championships Motorcycle Service Technology Contest Workstation 2 Electrical Troubleshooting Contestant Worksheet Contestant _________ The owner of the Yamaha motorcycle in your work area reports the lights dim down and eventually he can t electric start it If he charges up the battery everything works ok for awhile Because we can t run the motorcycle in the contest area assume the following a Battery is ok b When the engine is run up to 5000rpm the maximum voltage is 13 5 c There is only one problem on the bike 1 Using the multimeter supplied follow the troubleshooting steps in the service manual to check the electrical system On the lines provided below list each step you do and the results you found 2 List below the steps you fol
32. components changes reciprocation motion into rotary motion A rocker arm B camshaft D piston The intake port of a piston port two stroke engine typically B opens at BTDC and closes at ABDC C opens at BBDC and closes at ABDC D opens at BBDC and closes at ATDC 10 A two stroke engine with a leaking wet clutch side seal will exhibit which symptom A run lean C none of the above D all of the above Page 2 of 6 11 Changing 32 1 pre mix ration to 50 1 will A put more oil in the fuel oil mixture lubricate the engine better D have no effect 12 Overdrive is a gear that is numerically B more than 1 1 1 none of the above 13 If the transmission output sprocket has 14 teeth and the rear wheel sprocket has 44 teeth what would the final drive ratio be 2 333 1 318 1 40 000 1 14 Clutch drag is A the clutch does not transfer 100 of the engine s powerflow B clutch friction plates contaminated with oil D a clutch with worn out clutch springs 15 The largest driven gear found in a 5 speed indirect drive transmission will be 5 5 1 16 The four purposes of motor oil are A clean cool seal quiet C clean cool seal motivate D clean cool seal calcify Page 3 of 6 17 is a lubricating system that stores oil in a remote tank A wet sump B centrifugal C splash 18 a 20W 50 multi viscosity motor oil is one which
33. e if any fault codes on your work sheet Fault Code P1110 chive Intake Control Circuit Short LowOpen Description Historic Codes Clear Historic Fault Code Desenption Source No Fault Codes Present Next click on the circled DATA EI ITEMS icon 4MZHLO4DX83B00056 Record on your test sheet from the VALUE and UNITS column the requested items for questions 4 13 Additional values can be viewed by using the scroll bar on the right side of the data screen EA 2 O f Meters Graphe m Data Items Clear Hot Idle Hot Idle Limit Source Module Descnption Min Max Status Engine Speed Control Click on the circled MULTIMETER icon Data Items Data Items Clear Hot Idle Hot Idie Limit Source Module Descnption Value Units Min Status 1025 1165 E eser vs ws sm pe Eres Intake Aw Tempera F eStores 229 Baromeinc Pressure Sensor 95 Volts i i Manifold Absolute Pressure ow E Throttle Position 20 ECM Engine Speed ECM Idie Air Control Steps Fuel Pump Duty Fuel Pressure
34. e proper torque specification for the rear muffler strap bolts A 22 25 ft Ibs 22 52 ft 105 C 100 in Ibs D Good and tight 7 The lateral runout of the front tire should not exceed 20 A 8 000 B 2 030 C 0 800 D 0 080 E none of the above 8 The spark plug cable should have resistance of J ohms A 0 00 B 2 375 5 833 C 2 375 5 833 D infinity 9 The Pink PK wire at the ignitions coil connector 83B goes directly to the ignition module A True B False 10 On the ignition coil Cis 12 VDC ground the front cylinder s primary coil trigger the rear cylinder s primary coil trigger Domo 2 014 Ref Ignition Test 2 Neutral Switch Function Fig 7 31 Pg 7 27 for the next 3 questions 11 The vehicle set up or Condition for the test should be 220 A sidestand up key ON transmission in neutral and clutch engaged B sidestand up key ON transmission in neutral and clutch disengaged C sidestand down key OFF transmission in neutral and clutch engaged D sidestand down key ON transmission in neutral and clutch engaged 12 If the Voltage is found to be Battery Voltage minus 2 volts at the Diode 2 TN Y and the you should A check for continuity between TN Y and Diode 2 B check for ground at TN on Diode 1 C repair wiring D tell the customer that no faults were found 13 If the ground is not present at TN on Diode 1 you
35. f the measuring equipment The judge must insure all measuring equipment is zeroed Skills USA 2009 Motorcycle Service Technology Contest Workstation 1 Precision Measuring VRSC Valve Lash Adjustment amp Slipper Clutch Inspection Inventory per Workstation 14 fourteen workstations Description Part NumberFurnished by 1 VRSC Valve Lash Student Reference Guide H D 1 VRSC Slipper Clutch Student Reference Guide H D 1 0 1 50mm Metric Dial Caliper EDP 65910 H D 1 VRSC gauge set HD 47181 H D 1 Angled Feeler Gauge FB300A H D 1 0 25 Metric Micrometer 230m H D 1 6 steel ruler GAM2B H D 1 3 8 drive torque wrench 20 H D 1 Feeler gage set FB335 H D 1 3 8 Dr extension FXW4 H D 1 Blue Point Extension Magnet PT5B H D 1 3 8 dr 10mm shallow socket FM10 H D 1 3 8 dr ratchet FB16 H D Skills USA 2009 Motorcycle Service Technology Contest Workstation 1 Precision Measuring VRSC Valve Lash Adjustment amp Slipper Clutch Inspection Contestant Worksheet Contestant _____ Page 1 of 3 VRSC Valve Lash Adjustment 150 pts 1 Prior to checking the initial valve lash the camshafts must be orientated to what positions 2 Record all your valve lash measurements on the worksheet provided following the steps outlined in the VRSC Valve Lash Student Reference Guide 3 Using the Valve Lash Student Reference Guide briefly explain the purpose of the numbers and arrows that a
36. g Seat Install 16 Damper Spring with concave side up HARLEY DAVIDSON UNIVERSITY Direction of installation HARLEY DAVIDSON UNIVERSITY E v Tw Clutch Re Assembly Your assembled components should resemble the picture below 5704190 HARLEY DAVIDSON UNIVERSITY Clutch Re Assembly Slowly mate the pressure plate mon 2 onto the clutch hub assembly until it is fully seated DO NOT Force the clutch hub and pressure plate together recheck the alignment of the clutch plate tabs to the hub and pressure plate do not align under their own weight Verify that the clutch components are re assembled correctly by checking for any visible gaps between the clutch plates Check and verify that there are No visual gaps HARLEY DAVIDSON UNIVERSITY Clutch Re Assembly sm04507 e Re assemble the outer lifter plate with the four bolts and the clutch springs Gradually install the 4 fasteners using a crisscross pattern Do NOT tighten the 4 fasteners Leave the 4 fasteners loose at this point HARLEY DAVIDSON UNIVERSITY Clutch Re Assembly Shown with Clutch Disc TG uf Alignment Install the clutch hub spacer Note The photo is shown with the Clutch Disc Alignment Tool installed This is not needed until the final alignment in the upcoming pages HARLEY DAVIDSON UNIVERSITY 51103899 HARLEY DAVIDSON UNIVERSITY Cl
37. ge Set Up 1 The VRSC Valve Lash amp Slipper Clutch workstation tools consist of a Bench VRSC Cylinder head gt 3 5 Bench VRSC Slipper Clutch Assembly VRSC Cylinder Head Valve Lash Student Reference Guide VRSC Valve Lash Worksheets 2 VRSC Slipper Clutch Student Reference Guide VRSC Slipper Clutch Worksheets 2 Shop towels Calculator Black Marker VRSC Intake amp Exhaust Feeler gauges HD 47181 Blue Point Angled Feeler Gauge Set 0 25 Metric Micrometer 3 8 Ratchet 3 8 2 3 extension 10mm 3 8 drive socket Extension Magnet 3 8 40 200 in lb Torque Wrench Snap on QD2R200 Clutch Hub Alignment Tool HD 45654 0 150mm Dial Caliper 2 The cylinder head amp clutch assembly and all related items should be in plain view of the contestant It is important all tools necessary parts and information be readily available and visible to the contestant 3 VRSC Valve Shim container placed at a central location for all participants to access 4 The reference material tools parts should be organized on the table 5 Extra parts and miscellaneous equipment should be out of sight of the contestant Skills USA 2009 Motorcycle Service Technology Contest Workstation 1 Precision Measuring VRSC Valve Lash Adjustment amp Slipper Clutch Inspection 6 The judge needs to inspect the setting o
38. icipants will demonstrate the necessary skills to correctly disassemble the necessary VRSC valve train components adjust the valve lash and reassemble those components along with a complete disassembly inspection and reassembly of a VRSC Slipper Clutch Participants will determine this by use of precision measuring calculating and reading interpretation to determine the correct shim size and the condition of the clutch plates springs and components by comparing their results to the H D manufacturing specifications listed SPECIFIC SKILLS The contestant will Properly select and use precision measuring hand tools and equipment Locate specifications of the components in the resource materials Correctly dissemble VRSC cylinder head valve train components Measure and adjust the valve lash on a VRSC cylinder head Correctly reassemble VRSC cylinder head valve train components Correctly disassemble a VRSC Slipper Clutch Inspect and measure clutch plates Measure the free length of the clutch springs A Correctly reassemble a VRSC Slipper Clutch 10 Calculate measurements and determine component condition 11 Use tools and equipment properly and safely Skills USA 2009 Motorcycle Service Technology Contest Workstation 1 Precision Measuring VRSC Valve Lash Adjustment amp Slipper Clutch Inspection 12 Clean and reorganize the work area Instructions to Jud
39. ion calculate cylinder volume in cubic centimeters Bore 72 5 mm Stroke 60 3 mm A 248 394 cc B 497 868 cc C 248 934 cc D 34 336 cc 2 Pre ignition is spontaneous ignition after normal ignition auto ignition before normal ignition compression auto ignition after normal ignition oom 3 The intake valve opens in which quadrant A BTDC B ATDC C BBDC D ABDC 4 The exhaust valve opens in which quadrant A BTDC B ATDC C BBDC D ABDC Page 1 of 6 5 Valve occurs at the A end of the combustion stroke and the beginning of the exhaust stroke B end of the compression stroke and the beginning of the combustion stroke C end of the exhaust stroke and the beginning of the intake stroke D end of the intake stroke and the beginning of the compression stroke 6 Intake valve area is commonly that of the exhaust valve A greater than B the same as C less than D hotter than 7 The job of the camshaft is to A B C D drive the crankshaft dampen valve spring oscillations run the oil pump control when how fast how far how long the valve is opened 8 Which of these components changes reciprocation motion into rotary motion Domo rocker arm camshaft crankshaft piston 9 The intake port of a piston port two stroke engine typically A B C D opens at BTDC and closes at ATDC opens at BTDC and closes at ABDC opens at BBDC and closes at
40. lates use different spacing for the friction material compared to the remaining friction plates The friction material spacing is closer together than the other friction plates The assembly orientation for these 2 plates is also unique 1 narrow spaced friction plate is installed first and the remaining plate is installed last during assembly e 1 steel plate that utilizes a larger inside diameter than that of the other steel plates See the following page for more detail HARLEY DAVIDSON UNIVERSITY Clutch Re Assembly Component Identification Assembly Notes e Note the different spacing on the friction plates The narrow spaced friction plates are installed 1 amp last e Note that 1 steel plate will have a larger I D than the remaining steel plates e The inside diameter of the last steel plate prior to the narrow spaced friction plate will have a larger 1 0 HARLEY DAVIDSON UNIVERSITY VRSC Clutch Component Identification e 7 Clutch Hub 8 Steel Plate 7 9 Pressure Plate e 10 Clutch Springs 11 Lifter Plate Fasteners 14 Lifter Plate 15 Damper Spring Seat 16 Damper Spring 17 Narrow spaced friction plate 2 19 Wide spaced friction plate 7 26 Large Inside Diameter Steel Plate 1 HARLEY DAVIDSON UNIVERSITY Clutch Re Assembly Install 15 Steel Damper Sprin
41. low in troubleshooting the circuit Step Results 3 From the troubleshooting you have done what circuit or component is not working properly Stop 6 Leave this worksheet and pencil with the judge 2009 Skills USA Championships Motorcycle Service Technology Contest Workstation 2 Electrical Troubleshooting Judge s Score Sheet Contestant ______ Start Time ______ Judge s Initials ________ Stop Time ______ Total Time Scoring Directions Utiless otherwise specified the performance of each skill should be 0 1 2 using the following criteria 70 indicates that the contestant could not perform this skill 1 indicates that the contestant could partially perform this skill 2 indicates that the contestant could perform the skill 2 Student found correct sections of manual ____ 0 6 12 3 Steps followed to investigate problem Checked manual for charging system checks 0 6 12 Checked fuse assembly 0 6 12 Checked battery voltage en 0 6 12 Checked stator resistance ____ 0 12 24 Found stator has open wire ____ 0 12 24 4 Found stator to be bad DIE 0 15 30 5 JOB SKILLS Used tools safely and properly 0 6 12 Cleaned and organized the work area 0 6 12 TOTAL POSSIBLE SCORE 150 TOTAL Re Checking Final Valve Corrected Measurement HARLEY DAVIDSON UNIVERSITY Record New Valve Lash Measurement 20
42. ment Verify the DVOM is functioning properly 4 Verify the vehicle battery is fully charged them for the next participant must set up for the next contestant Inventory per Workstation four workstations Oty Description I lI Il l3 l3 Test booklet Battery Tender Global Battery Charger Test Leads and clips Extension Cord for battery tender if needed Fluke 789 Processmeter DVOM Digital Technician computer and power cord Techlink Il USB Cord Techlink to USB Computer Port Fluke Optical Cord Meter to USB Port on Computer Flashlight Part NumberFurnished by The instruction manual and tools should be organized on the table The judge should monitor the participant s progress to ensure safe use of the The contestant should turn off the DVOM unhook the leads and properly prepare If the contestant does not finish the prescribed work in the time allotted the judge 94654 98 HD 48650 1 H D H D H D H D H D H D H D H D H D H D SkillsUSA 2009 Motorcycle Service Technology Contest Workstation 5 Digital Technician Diagnostics Contestant Worksheet Contestant 2 Vehicle Mileage 3 Active and or Historic Fault Code Numbers 4 Idle Air Control Steps 5 Fuel Pressure These answers from page 8 in your test 6 Battery Voltage booklet 7 Engine Coolant Temperature 8 Intake Air Temperature Sensor Degrees 9 Barometric Pressure In
43. n Test Motorcycle Technology Theory Sponsored by L 2 2 YCLE MECHANICS INSTITUTE A DIVISION OF UNIVERSAL TECHNICAL INSTITUTE SkillsUSA 2009 Motorcycle Service Technology Contest Motorcycle Technology Theory Objective This written test allows the participant to demonstrate knowledge of Motorcycle Technology Theory Directions Select the best answer s for each question and then fill in the appropriate letter s box on the answer sheet provided 1 Using the following information calculate cylinder volume in cubic centimeters Bore 72 5 mm Stroke 60 3 mm A 248 394 cc B 497 868 cc D 34 336 cc 2 Pre ignition is A spontaneous ignition after normal ignition C compression D auto ignition after normal ignition 3 The intake valve opens in which quadrant A BTDC B ATDC C BBDC D ABDC 4 The exhaust valve opens in which quadrant A BIDC B ATDC D ABDC Page 1 of 6 Valve overlap occurs at the A end of the combustion stroke and the beginning of the exhaust stroke B end of the compression stroke and the beginning of the combustion stroke D end of the intake stroke and the beginning of the compression stroke Intake valve area is commonly that of the exhaust valve B the same as C less than D hotter than The job of the camshaft is to A drive the crankshaft B dampen valve spring oscillations C run the oil pump Which of these
44. nt in the exhaust gas and converts it to a voltage reading 0 1 2 7 The IAT pg 4 105 sensor measures the air temperature allowing the ECM to calculate the density of the air entering the manifold __ 0 4 8 Il JOB SKILLS 1 Cleaned and organized the work area _ 0 4 8 Total Possible Score 100 2009 Skills USA Championships Motorcycle Service Technology Contest Workstation 5 Buell Digital Technician Diagnostics Sponsored by Buell Motorcycle Company SkillsUSA 2009 Motorcycle Service Technology Contest Workstation 5 Digital Technician Diagnostics Objective Information Sheet Time Limit 30 Minutes OBJECTIVE Given the tools motorcycle and Instruction Sheet participants will correctly test and record vehicle data on a 08 Buell 1125R motorcycle SPECIFIC SKILLS The contestant will 1 Follow the instructions outlined in the supplied test booklet to correctly test and record the requested vehicle data using the Digital Technician diagnostic computer Use a digital multimeter to properly measure voltage for the requested battery data Evaluate multimeter test results to determine component state or condition Use the tools and equipment properly and safely 2 N Clean and reorganize the work area Skills USA 2009 Motorcycle Service Technology Contest Workstation 5 Digital Technician Diagnostics Instructions to Judge Set Up equip
45. ons D reduce HC emissions Air density A refers to the amount of oxygen in a given space B decreases as altitude decreases C affects the pressure differences D increases and altitude increases An air fuel ratio of 12 1 has A 12 parts air by volume to 1 part fuel B 1 part air by volume to 12 parts fuel C 12 parts air by weight to 1 part fuel D 12 parts fuel by weight to 1 part air The force that results from an electrical pressure difference is called A watts B ohms C amps D EMF 5 of 6 29 Which of the following formulas is correct A Volts Amps X Ohms B Volts X Ohms Amps Ohms Amps Volts D Amps Volts Watts 30 The two major types of charging systems are A rising field collapsing field B excited field normally open C permanent magnet full wave D permanent magnet electromagnet 31 The three strengths of charging systems are A half wave full wave permanent magnet B half wave full wave sine wave C half wave full wave 3 phase D permanent magnet electromagnet rising field 32 The ignition coil s winding A solenoid starter B field stator C secondary primary D primary secondary 33 An ignition coil operates on the principle of A polarity B grounding C residual magnetism D mutual induction SkillsUSA 2009 Motorcycle Service Technology Contest KEY Written Test Answer Sheet Motorcycle Technology Theory Sponsored by
46. ovide the most efficient stoichiometric air fuel mixture which results in reduced emissions good fuel economy and power 2 of 2 5 The and sensors are thermistor devices which means that at a specific temperatures they will have a specific resistance across their terminals As the resistance varies so does the voltage supplied 6 The sensor monitors the oxygen content in the exhaust gas and converts it to a voltage reading 7 The sensor measures the air temperature allowing the ECM to calculate the density of the air entering the manifold STOP Leave this worksheet and pencil with the judge SkillsUSA 2009 Motorcycle Service Technology Contest Workstation 4 Buell DDFI Component 1 0 6 Function Judge s Scoresheet Contestant ____ Start Time _______ Stop Judge s Initials __________ Scoring Directions Unless otherwise specified the performance of each contestant should be 0 or 5 or for the questions 3 7 and job skills 4 or 8 using the following criteria indicates the contestants answer is incorrect 4 indicates the contestants answer is partially correct Where applicable 5 or 8 indicates the contestants answer is correct PERFORMANCE 1 Using the service manual identify the numbered components on the DDFI Simulator Board and record your answer next to the corresponding number listed below 1 Electronic Con
47. r bucket design to increase the valve lash clearance a technician must find a smaller or larger shim _Smaller Total Number of Points _______ 0 10 With a shim under bucket design to decrease the valve lash clearance a technician must find a smaller or larger shim _Larger Total Number of Points _______ 0 10 Combined Total Possible Score for VRSC Valve Lash 150 Contestant Total Score for VRSC Valve Lash PERFORMANCE VRSC SLIPPER CLUTCH INSPECTION 150 PTS 2009 Motorcycle Service Technology Contest VRSC Valve Lash Adjustment amp Slipper Clutch Skills USA Workstation 1 Precision Measuring Inspection Page 3 of 4 7 1 Accurately measured and recorded clutch components Compare student measurements in all recorded columns to factory specifications listed in the table Place a check mark in the appropriate space to indicate a good measurement for each column and the full score amount of 25 Or place a check minus 4 to indicate a measurement that is narrowly out of specification allocating a partial score amount of 15 Or place an X in the space to indicate an inaccurate measurement and a zero score en Measurements Specification 25 pts each Clutch Spring Free Length Factory Shee mm 42 42 42 42 Clutch Friction Plates en 3 62mm 3 62mm 3 62mm 3 62mm 3 62mm 3 62mm 3 62mm 3 62mm 3 62mm Steel Plates Warpage m 0 15mm 0 15mm 0 1
48. re associated with the camshaft journal caps a 4 Record the torque specification for the cam journal caps a Specification ______________ 5 With a shim under bucket design to increase the valve lash clearance a technician must find a smaller or larger shim 6 With a shim under bucket design to decrease the valve lash clearance a technician must find a smaller or larger shim Upon cylinder head reassembly you are ready to move on to the Slipper Clutch Inspection Skills USA 2009 Motorcycle Service Technology Contest Workstation 1 Precision Measuring VRSC Valve Lash Adjustment amp Slipper Clutch Inspection Page 2 of 3 VRSC Slipper Clutch Inspection 150pts Record all your clutch component inspection measurements on the worksheet provided following the steps outlined in the VRSC Slipper Clutch Student Reference Guide The damper spring is installed onto the damper spring seat with the concave side There are two unique Friction Plates How are these installed in relationship to the other friction plates Skills USA 2009 Motorcycle Service Technology Contest Workstation 1 Precision Measuring VRSC Valve Lash Adjustment amp Slipper Clutch Inspection Page 3 of 3 6 Describe where the larger inside diameter steel plate is installed within the clutch assembly This completes the Harley Davidson Precision Measuring Workstation Stop Leave
49. should A punch out and go home early B check for ground at the neutral switch terminal C check Diode 1 with an ohmmeter D replace the Diode 14 The m circled 4 in the flow chart instructions on page 7 65 indicates that A the seat should be removed B order in which the tests are to be done C a continuation point from another test flow chart D the test needs to be done 4 times 15 Terminal 8 of the Instrument Connector 20 is J A a Black BK wire B a Red R wire C a Green Yellow GN Y wire D not used 16 The specified torque for the lifter anti rotation screws is 1 A 3 5 Nm B 15 19 ft 105 C 80 110 in 105 D 55 65 in lbs E none of the above 3 014 17 The Speedometer Diagnostic code indicating power over voltage is 1 B d08 C CAL 14 D d10 18 When performing the Speedometer Performance Check with the Speedometer Tester HD 41354 a frequency of 1803 Hz should reflect a speedometer display of MPH on a USA market meter A 20 B 40 C 60 D 80 19 The exhaust push rod is identified by a colored band A Black B White C Pink D Orange 20 The Throttle Position Sensor TP Voltage is checked with the throttle plate fully closed and should have a reading of A 45 55 VDC B 45 55 ohms C 5 5 VDC D 5 05 VDC SkillsUSA 2009 Motorcycle Service Technology Contest ANSWERS Writte
50. t oil combined B thickens less when cold than a 20 weight and thins less when hot that a 50 weight C is a 20 weight mixed with 30 weight D thins less when cold than a 20 weight and thickens less when hot than a 50 weight 19 The component found in the oil filter that allows oil to flow if the filter becomes clogged is the A oil pressure relief valve B bypass valve C reed valve D oil pump 20 The bearing which is the best for radial loads but not at all good for axial loads is the A thrust bearing B tapered roller bearing C ball bearing D roller bearing 21 Which one of these is one of the four purposes of bearings A support radial and or axial loads B lubricate C impressibility D permeability 22 In a liquid cooling system the thermostat A allows for quicker engine warm up time B determines the cooling system s operating pressure C is a heat exchanger D sends electrical data to the instrument panel 4016 23 Ina cooling system the determines the cooling system s operating pressure A thermostat B water pump C radiator D radiator cap 24 25 26 27 28 Octane is the fuel s ability to A increase mechanical efficiency B resist chemical breakdown C resist detonation D increase stroke efficiency The main purpose of oxygenated fuels is to A improve fuel mileage of the engine B reduce CO2 emissions C reduce CO emissi
51. torcycle Service Technology Contest Workstation 4 Buell DDFI Component 1 0 amp Function Instructions to Judge Set Up 1 The DDFI Simulator Board and service manual should be organized on the worktable 2 DDFI Simulator Board should be plugged in and checked for operation Inventory per Workstation four workstations Description Part Number Furnished by 1 2004 Buell Lightning Service Manual 99490 06Y H D 1 Buell DDFI Simulator Board 1 Extension cord H D H D SkillsUSA 2009 Motorcycle Service Technology Contest Workstation 4 Buell DDFI Component 1 0 6 Function Contestant Worksheet Contestant Page 1 of 2 1 Using the service manual identify the numbered components on the DDFI Simulator Board and record your answer next to the corresponding number listed below 1 2 3 4 5 6 7 8 9 2 Using the Service Manual identify the lettered Fuel Pump components on the DDFI simulator board and record your answers next to the corresponding letter listed below A B C Using the service manual answer the following questions 3 The DDFI System uses number of sensors to monitor the operating conditions of the engine Skills USA 2009 Motorcycle Service Technology Contest Workstation 4 Buell DDFI Component 1 0 amp Function 4 During closed loop operation the system relies on input from the sensor to pr
52. trol Module ECM 4 3 lists all components 2 Cam Position Sensor amp Rotor CMP 3 Oxygen Sensor 02 __ 0 5 4 Engine Temperature Sensor ET 5 Bank Angle Sensor BAS 0 5 6 Intake Air Temperature Sensor IAT 7 Throttle Position Sensor TP 8 Fuel Pump 0 5 9 Throttle Body 0 5 SkillsUSA 2009 Motorcycle Service Technology Contest Workstation 4 Buell DDFI Component 1 0 amp Function 2 Using the Service Manual identify the lettered Fuel Pump Components on the DDFI simulator board and record your answers next to the corresponding letter listed below pg 4 110 A Fuel Screen __ 0 5 Low Fuel Level Sensor __ 0 5 C _Pressure Regulator __ 0 5 SkillsUSA 2009 Motorcycle Service Technology Contest Workstation 4 Buell DDFI Component 1 0 6 Function Using the service manual answer the following questions 3 The DDFI System uses 6 pg 4 3 number of sensors to monitor the operating conditions of the engine __ 0 4 8 4 During closed loop operation the system relies on input from the 02 pg 4 3 __ sensor 0 4 8 5 The pg 4 52 __IAT pg 4 56 sensors are thermistor devices which means that at specific temperature they will have specific resistance across its terminals As the resistance varies so does the voltage supplied __ 0 4 8 6 The 02 pg 4 47 or 4 101 sensor monitors the oxygen conte
53. utch Re Assembly Install the Clutch Disc 0 Alignment Spacer into i the back side of the Z P Alignment clutch basket 290 This is used center and square up the clutch pack to ease reassembly HARLEY DAVIDSON UNIVERSITY Clutch Re Assembly e Check your work e Using a cross pattern tighten the 4 lifter plate fatteners to 9 7 Nm 86 in Ibs 51103899 HARLEY DAVIDSON UNIVERSITY Clutch Re Assembly Remove the Clutch Disc Alignment Spacer Double check your work Complete your worksheets Clean and organize your workstation and area Upon completion call the judge over to collect your worksheets and check your work area Congratulations You have completed this workstation HARLEY DAVIDSON UNIVERSITY HARLEY DAVIDSON UNIVERSITY EN TERN gt gt Harley Davidson VRSC Valve Lash Adjustment Workstation Student ER zu VRSC Valve Lash Instructions Cam nose area sm01847 between circle 15 anywhere below the red line HARLEY DAVIDSON UNIVERSITY gt 0 fc Lu gt 5 0 gt lt 5 gt cc lt T gt 0 0 gt lt 5 gt LU nc lt HARLEY DAVIDSON UNIVERSITY Checking VRSC Valve Measurement with a feeler gauge HARLEY DAVIDSON UNIVERSITY Recording your Valve Lash Measurement 2009 HA
54. ycle Service Technology Contest Workstation 3 Carburetor Inspection Contestant Worksheet 5a Jet needle What is the jet needle number currently in this carburetor 5b What is the correct number jet needle 5c What is the correct clip position 6a Pilot air screw setting what is standard setting for this air screw 6b If the air screw is turned out more than standard what effect is there on air fuel ratio 7a Altitude adjustment this carburetor is set from the factory for sea level If the carburetor needed to be reset for high attitude would the main jet be a smaller number or larger number 7b At higher altitudes what happens to the fuel air ratio if the carburetor is set for sea level In the float bowl there is a hole that has a paint dot next to it What is the purpose of this hole 8b What effect would there be on carburetor function if it were plugged 9 Once finished put the carburetor back together as you found it 10 Please return the carburetor manuals etc in the position you found them Stop 11 Leave this worksheet and pencil with the judge 2009 SkillsUSA Championships Motorcycle Service Technology Contest Workstation 3 Carburetor Inspection Judge s Score sheet Contestant Start Time Judge s Initials ____ Stop Time ______ Total Time Scoring Directions Unless otherwise specified the performance of each skill should be 0 3

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