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Motorcycle Maintenance Service Checklist

This document provides a motorcycle maintenance service checklist. It lists various parts that should be inspected or serviced, including electrical equipment, tires, brakes, engine, transmission, and other components. Technicians are instructed to check pressures, levels, wear, leaks, adjustments, and torques. An overview section also outlines procedures for overhauling the engine, such as inspecting the cylinder head, valves, piston rings, camshaft, and other internal parts. The checklist aims to ensure the motorcycle is properly maintained through inspection and servicing of key systems and components.

Uploaded by

Jaymar Bobier Duculan
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242 views5 pages

Motorcycle Maintenance Service Checklist

This document provides a motorcycle maintenance service checklist. It lists various parts that should be inspected or serviced, including electrical equipment, tires, brakes, engine, transmission, and other components. Technicians are instructed to check pressures, levels, wear, leaks, adjustments, and torques. An overview section also outlines procedures for overhauling the engine, such as inspecting the cylinder head, valves, piston rings, camshaft, and other internal parts. The checklist aims to ensure the motorcycle is properly maintained through inspection and servicing of key systems and components.

Uploaded by

Jaymar Bobier Duculan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd

Motorcycle Maintenance Service Checklist

ITEM SERVICED PROCEDURE CONDITION RECOMENDATION


Electrical equipment and switches Check operation

Front tire Check pressure, inspect tread

Front wheel spokes (if equipped) Check tightness with torque wrench

Front brake fluid Inspect sight glass

Clutch fluid/linkage (hydraulic operated) Inspect sight glass/linkage

Hand control fasteners Check switch housing screw torque

Check clutch/brake lever handlebar clamp


screw torque/free play
Check master cylinder handle- bar clamp
screw torque
Steering head bearings Inspect lash clearance

Air cleaner Inspect, service as required

Engine oil and filter Inspect level/appearance

Engine coolant Check freeze point, inspect for leaks

Replace coolant
Clean radiators
Transmission lubricant Inspect oil level/appearance

Right front engine mount end cap screws Check torque

Engine mount to front crankcase Check torque


screws
Oil lines and brake system Inspect for leaks, contact, or abrasion

Fuel lines and fittings Inspect for leaks, contact, or abrasion

Rear brake fluid/linkage Inspect sight glass/linkage

Brake pads and discs Inspect for wear

Front axle nut Check torque

Clutch cable Check adjustment

Brake and clutch controls Check, adjust, and lubricate with


recommended lube
Name: ______________________________ Date: ________________
Rear wheel spokes (if equipped) Check tightness with torque wrench

Rear tire Check pressure, inspect tread

Drive belt and sprockets Inspect, adjust belt

Rear axle nut Check torque

Exhaust system Inspect for leaks, cracks and loose or missing


fasteners, or exhaust shields

Battery Check battery, terminal torque, and clean


connections. Lubricate terminals with
ELECTRICAL CONTACT LUBRICANT.

Spark plugs

Front/rear forks and shocks Inspect leaks

Fuel filter element

Rear sprocket isolators

Road test Verify component and system functions.

ELECRICAL SYSTEM COMPONENT


ITEM SERVICED PROCEDURE CONDITION RECOMENDATION
Ignition system Check
OVERHAULING ENGINE
ITEM SERVICED PROCEDURE CONDITION RECOMENDATION
Cylinder head Inspect surface

Intake/exhaust Valve Inspect appearance

Piston ring Check Gap

Piston Inspect possible scoring

Cam shaft Inspect appearance

Cam shaft bearing Inspect lash play

Cylinder bore Inspect possible scoring

Valve spring Check height

Pushrod (if applicable) Check straightness

Piston pin

Connecting rod small end

Connecting rod

Crank shaft Inspect lash clearance

Side bearings Inspect excessive play

Clutch hub Inspect dumper

Clutch lining and plates Inspect appearance

Clutch spring Inspect tension


Clutch pressure plate Inspect facing

Transmission gears Inspect appearance

Transmission bearings Inspect clearance/play

Transmission shaft Inspect appearance

Shift drum/fork Inspect appearance

Transmission case Inspect appearance

Shifter rod Inspect

Transmission bearing Inspect lash play

Name: ______________________________ Date: ________________

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