Motorcycle Technician Course

Lesson 1 • Shop Safety and Hazard Control

Identifies chemical, electrical, and mechanical hazards common in motorcycle shops. Builds habits that protect technicians throughout the course.

Lesson 2 • Motorcycle Industry Overview

Covers motorcycle market segments, manufacturer types, and technician career paths. Provides context for all subsequent technical training.

Lesson 3 • Hand Tools and Measuring Instruments

Introduces standard hand tools, torque wrenches, and precision measuring devices. Correct tool selection underpins every repair task in later chapters.

Lesson 4 • Motorcycle Systems Identification

Maps the major systems of a motorcycle and their functional relationships. Students gain a mental framework for diagnosing and organising repair work.

Lesson 1 • Top-End Inspection and Rebuild

Covers cylinder, piston, and ring measurement and replacement on two-stroke engines. Students perform a complete top-end rebuild using precision tools.

Lesson 2 • Two-Stroke Bottom-End Service

Addresses crankshaft, main bearings, and crankcase splitting on two-stroke engines. Proper assembly ensures correct port timing and oil sealing.

Lesson 3 • Two-Stroke Engine Design

Details port timing, reed valves, and power valve systems unique to two-stroke engines. Understanding design differences guides correct service procedures.

Lesson 1 • Multi-Cylinder Engine Balancing

Introduces carburation synchronisation, ignition timing balance, and compression equalisation across cylinders. Balanced cylinders maximise power and smoothness.

Lesson 2 • Cylinder Head Inspection and Rebuild

Covers valve lapping, seat cutting, spring testing, and head gasket replacement. Students restore head sealing and flow characteristics to specification.

Lesson 3 • Piston, Rings, and Cylinder Service

Addresses four-stroke piston inspection, ring gap setting, and cylinder reconditioning. Proper clearances prevent oil consumption and premature wear.

Lesson 4 • Valve Train Systems and Adjustment

Explains OHC and OHV valve train layouts, cam timing, and clearance adjustment. Correct valve clearance directly affects engine performance and longevity.

Lesson 1 • Carburettor Theory and Service

Explains carburettor circuits, jet sizing, and float level adjustment. Mastery of carburettors prepares students to understand fuel injection by contrast.

Lesson 2 • Emissions Systems and Compliance

Explains evaporative emission controls, secondary air injection, and exhaust gas analysis. Technicians must restore emission systems to regulatory standards.

Lesson 3 • Fuel Injection System Diagnosis

Covers injector testing, fuel pressure measurement, and throttle position sensor calibration. EFI diagnosis relies on systematic sensor and actuator testing.

Lesson 4 • Air Intake and Filtration

Addresses air filter types, intake boot inspection, and airbox modification effects. Proper intake flow is essential for accurate fuel mapping.

Lesson 1 • Starting and Lighting Systems

Covers starter motor testing, solenoid diagnosis, and lighting circuit troubleshooting. These systems are among the most frequent customer complaints.

Lesson 2 • Electronic Control Units and Sensors

Introduces ECU inputs, sensor signal patterns, and scan tool data interpretation. ECU diagnosis integrates electrical skills with fuel and ignition systems.

Lesson 3 • Battery and Charging System Service

Covers battery load testing, stator output measurement, and regulator-rectifier diagnosis. A healthy charging system is verified before ignition testing.

Lesson 4 • Ignition System Diagnosis

Addresses CDI, TCI, and coil-on-plug ignition systems, including timing and spark testing. Correct ignition timing is critical for engine performance and emissions.

Lesson 1 • Clutch System Inspection and Service

Addresses wet and dry clutch designs, friction plate measurement, and cable or hydraulic adjustment. Clutch condition directly affects transmission shift quality.

Lesson 2 • Automatic and CVT Transmission Service

Explains variator, drive belt, and centrifugal clutch service on scooter-type CVT systems. CVT service differs fundamentally from manual transmission work.

Lesson 3 • Manual Transmission Overhaul

Covers gear inspection, shift fork measurement, and bearing replacement in constant-mesh transmissions. Precise assembly prevents false neutrals and gear jumping.

Lesson 4 • Chain, Belt, and Shaft Final Drive

Covers chain slack adjustment, sprocket wear, belt tension, and shaft drive oil service. Final drive condition affects handling, tyre wear, and power loss.

Lesson 1 • Drum Brakes, ABS, and Traction Control

Addresses drum brake adjustment, ABS wheel speed sensor testing, and traction control calibration. Advanced brake systems require both mechanical and electronic skills.

Lesson 2 • Rear Suspension Service

Covers mono-shock and twin-shock disassembly, linkage bearing replacement, and spring rate selection. Rear suspension balance complements front fork setup.

Lesson 3 • Front Fork Service and Setup

Addresses conventional and inverted fork disassembly, seal replacement, and oil volume setting. Fork condition governs front-end stability and rider feedback.

Lesson 4 • Hydraulic Brake System Overhaul

Covers master cylinder and caliper rebuild, brake fluid flush, and rotor measurement. Hydraulic brake integrity is a primary safety requirement.

Lesson 1 • Intermittent and No-Start Diagnosis

Addresses thermal, vibration-induced, and load-dependent faults using data logging. Intermittent faults require patience and methodical data collection.

Lesson 2 • Quality Control and Final Inspection

Establishes pre-delivery inspection checklists, torque verification, and test ride protocols. Final inspection prevents comebacks and ensures customer safety.

Lesson 3 • Oscilloscope and Advanced Test Equipment

Covers oscilloscope waveform capture for sensors, injectors, and ignition signals. Advanced tools reveal intermittent faults invisible to basic multimeters.

Lesson 4 • Estimating, Pricing, and Workflow

Covers labour time estimation, parts markup, and repair order workflow in a production shop. Accurate estimates protect shop profitability and customer trust.