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Reaming is a fine finish by reamer,which can increase the precision degree of holes on parts and decrease
the roughness degree.It improves the match precision between hole and shaft and the precision can reach
grade 6 to grade 8. The basic tool for reaming is a reamer,such as fixed reamer,adjustable reamer,conical reamer
and so on.Before reaming,we need to drill a bottom hole in advance,which is for the precision requirement of hole
shaped and making room for reaming procedure.
[5]Tapping and thread die cutting
Tapping is to Process internal thread with screw tap and thread die cutting is to process external thread with
threading die. The essential tools for tapping is screw tap. Generally, screw tap consist of master tap and plug tap.
The difference between these Two kinds of tap is that master tap adopt a slight bevel angle on cutting part,instead ,
plug tap adopt a steeply bevel angle. After tapping,we should drill a bottom hole with chamfer.
Please refer to the specialized list or the following formula for the bit diameter of bottom hole :
Diameter of drilling hole outside diameter of screw thread - 1.1mm × screw pitch(appropriate for iron and
copper)
Diameter of drilling hole outside diameter of screw thread-1.2mm × screw pitch(appropriate for steel and brass)
When cutting inside threads,turn master tap into the chamfer-angle hole,then take out and use plug tap to shape
the threads.
The tool for outside screw threads cutting is screw plate.Screw plate includes fixed screw plate,adjustable screw
plate and active screw plate.Usually,we use fixed screw plate,i.e.round screw plate.When cutting outside screw
threads,choose screw plate and diameter of club-shaped material according the required material,diameter of screw
thread and screw pitch.To make proper choice,please refer to the specialized list or the following formula:
Diameter of club shaped materialoutside diameter of screw thread-0.13mm × screw pitch
Bevel the end of club-shaped material in 15 °～20°angle before cutting outside screw threads.To ensure easy
operation,the screw plate and club-shaped material should be in vertical,therefore,the minimum diameter of cone
angle should less than inside diameter of screw thread.
[6]Rectification
The operation that eliminates the unevenness of plane-shaped,bar-shaped and column-shaped parts is called
rectification.。Rectification can reshape the parts.
The rectification depends on the flexibility of metal parts.Therefore,metal parts with good flexibility can be
rectified directly,such as soft steel and red cooper ' metal parts with less flexibility need to anneal before rectification.
The ways for rectification are torsion,extension,bending and expansion.
[7]Bonding
Bonding is widely used in manufacture and repairs because it operates easily and can be done without special
equipment and expensive materials. In addition,the bonding parts don 't need to be processed by high precision
machine,such as the bonding of handlebar and steering head,bonding of plastic label and spay-paint metal parts,
bonding of brake disc and brake pads.There are various adhesive,such as epoxy adhesive,phenol formaldehyde
adhesive and so on.
（5）Motorcycle assembly
The last procedure in repair is assembly,which is a key to ensure the good quality of motorcycle.
[1]Assembly includes module assembly,parts assembly and overall assembly.In the process of assembly,we
should abide by the principle that assemble module first,then parts and the overall finally.The sequence of assembly
is opposite to disassembly,which is to first assemble the last disassembled components,and to last assemble the first
disassembled components.
[2]Module assembly is the first stage in whole process,which makes the parts into a single module,such as the
combination of front brake drum cover,the combination of brake pads ,the combination of wheel.
[3]Parts assembly is based upon module assembly,which assembles the parts and module as a whole,such as
front and rear wheel assembly,front fork assembly,shock absorber assembly and so on.
[4]Overall assembly is the last procedure to complete the whole working process,which connects parts and
modules with frame according to installation sequence by all means.
[5]The sequences of overall assembly are similar.The operation is as following ：Firstly,finish all modules
assembly and parts assembly,then install engine assembly and gearbox assembly on frame.Secondly,install front fork
assembly,handlebar assembly,front and rear fender assembly,shock absorber assembly,carrier assembly,front and
rear wheel assembly,fuel tank assembly and seat assembly.Thirdly,install headlight,taillight,steering indicator,horn
and battery assembly.The fourth,connect all electric circuit and control cables.The fifth,install driving chain, dentiform
belt,wind shield and chain cover or belt cover.Last,lubricate the whole motorcycle.
[6]Consult the following reference about disassembly,installation and inspection if there is any assembly se-
quence difference which is caused by different type and structure.
[7]Pay attention to the following: ：
Choose a clean and wide place ；strictly follow the assembly requirements；parts connecting should accord
with specification ;avoid misfitting and leaving out of any gaskets,cotter pin and fixing clip.
3 Adjustment after Repair
The interconnection of parts have been affected in some extent after repair.To recover the performance of
motorcycle,adjust them according to the specification of user 'smanual.adjust as follows:
7
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