SERVICE MOTORCYCLE/SMALL

ENGINE SYSTEM (UOC)

AUTOMOTIVE / LAND TRANSPORTATION

Service fuel system (LO)

AUTHOR: Roddel Dean M. Sicat.

If you have any concern or questions for our reading materials, I am
available every day Monday to Friday @ 10:00am to 12:00pm, you
can ask me a question by FB Group Page Name is Motorcycle Small
Engine Serving NCII or contact to this #: 09267709829.
This Google Classroom: (Class code lp7mrvi) will be used in our
online class and other like quizzes and assignment and module for
our topic.

Module Descriptor
Introduction
This competency covers the knowledge, skills and ability to inspect,
diagnose, adjust and service the fuel, intake and exhaust, lubrication,
cooling, transmission and clutch system and its components where
applicable to motorcycle/small engine units.

Training outline
 Lesson 1:Service fuel system
 Lesson 2:Service intake and exhaust system
 Lesson 3:Service lubrication system
 Lesson 4:Service cooling system
 Lesson 5:Service transmission, and clutch
system (for motorcycle)
 Lesson 6: Clean-Up Work Area.
TABLE OF
CONTENTS

Definition of Terms.............................................................................................4
INFORMATION SHEET 1.1-1.................................................................................5,8
INFORMATION SHEET 1.1-2...........................................................................9,35
INFORMATION SHEET 1.1-3..................................................................................
Exhaust system.........................................................................................................
Cooling system.........................................................................................................
Definition of Terms

A. MOTORCYCLE COMPONENTS:

 Engine- converts the heat energy generated by combustion explosion

of fuel into mechanical energy (rotational force).
 Fuel intake system - converts the gasoline fuel into a readily
explosive air-fuel mixture and delivers it to the engine.
 Lubrication system - Protects moving metal parts with a film of oil,
reduces friction and provides cooling to enable smooth operation.
 Exhaust system - Quietly discharge the high pressure exhaust gas to
a reduced pressure and reduced temperature.
 Cooling system - Maintains the proper engine temperature for
smooth operation.
 Clutch mechanism - Transfers or stops the transmission of engine
power to the gear mechanism
 Gear mechanism - Enables the required power and engine speed for
riding to be selected as necessary.
 Transmission - Transfers the power from the gear mechanism to the
rear wheel.
 Starter mechanism - Transmits the rotation of the kick crank to the
crankshaft, and rotates the crank
 Ignition system - Creates the high voltage electrical spark to ignite the air-fuel
mixture necessary for engine operation.
 Power supply, dynamo mechanisms - provide power for each electrical device
for continuous operation.
 Signals, lighting mechanisms - Illumination and signals for safe riding, and
safety equipment such as various gauges
 Starter system - used to turn the crankshaft by electrical power to start the
engine.

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 INFORMATION SHEET 1.1-1

GENERAL INTRODUCTION

(Motorcycle unit: Systems & Servicing)

After reading this INFORMATION SHEET, YOU MUST be able to:

1. Explain the systematic approach of servicing the motorcycle unit in
general.
2. Understand the implications of developing oneself as authentic skilled
mechanic.
3. Explain the interrelations of all the systems of the motorcycle unit in
view of developing skills in
trouble shooting.
4. Explain the importance of the service manual as guide for servicing
the motorcycle unit.

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 1. Engine System
a. Power generation system
b. Power transmission System

a. The power generation system for riding is comprised of the following systems:
 Engine
 Fuel intake system
 Lubrication
 Exhaust system
 Cooling system
b. Power transmission System for riding is comprised of the following systems
 Clutch mechanism
 Gear mechanism
 Transmission
 Starter mechanism

2. Electrical System
Electrical Mechanisms:
Electrical power creates the ignition spark for engine operation and operates various features
for safe riding.

They comprise the following mechanisms:

 Ignition system
 Power supply, dynamo mechanisms
 Signals, lighting mechanisms
 Starter system

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 3. Chassis (Riding and Steering Mechanisms)
Comprised of mechanisms required for riding, and mechanisms for steering
operation. 

 Basic chassis
 Steering shock absorber mechanism
 Rear wheel shock absorber mechanism
 Wheels and braking mechanism
 Others: Fuel tank, cock, seat, fender, etc.

Basic Information on Motorcycle engines:

As our basic understanding of engine as a device used to convert the
heat energy generated by combustion
explosion of fuel into mechanical energy (rotational force) and
classified as internal combustion engine.

Classifications Internal Combustion Engines:

By Fuel type:
1. Gasoline engine (Carbureted / Fuel injected)
2. Diesel engine (light oil)

By type of motion:
1. Reciprocating engine
2. Rotary engine

By type of ignition system:

1. Spark Ignition engine
2. Compression Ignition engine

By Cycle of operation:
 4 cycle engine
 2 cycle engine

By engine design:
1. Overhead Valve (OHV)
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 2. Overhead Camshaft (OHC)
3. Side Valve (SV)

Presently, the mainstay of engines for MOTORCYCLES:

 Gasoline engine
 Reciprocating engine (Cylinder/ Piston: Bore/Stroke)
 Spark ignition
 4 strokes /cycles engines (2 stroke, being phased out; non-
environment-friendly)
 Air-cooled
 Water cooled (on sports type and larger in size)

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 INFORMATION SHEET 1.1-2

THEORETICAL BACKGROUND: Carbureted Engine Fuel System

Learning Objectives:
After reading this INFORMATION SHEET, YOU MUST be able to:
a. Understand the basic terms related to the engine and its operation.
b. Explain thoroughly how the three (3) essential factors as necessary
conditions for proper engine operation.
c. Explain the basic function of each part of the engine and its design
for specific purpose in relation to servicing.
d. Explain the 4 events of an engine cycle with the piston position,
firing timing, and the intake /exhaust valves positions.
e. Explain the basic operation of carburetor as air/fuel mixing device
with the different throttle positions from idling to full throttling
f. Describe the procedure of setting the carburetor for idle speed for
TMX 155.

ENGINE: INTRODUCTION

A. BASIC TERMS

1. CYCLE: consists of four (4) events/actions: Intake,

Compression, Combustion, Exhaust.
“intake” air/fuel mixtures,
“compress”,
“burn” and
- “exhaust” the burnt gases in cycles.
For 2 stroke = 1 cycle with 1 complete rotation of crankshaft
For 4 stroke= 1 cycle with 2 complete rotations of crankshaft

2. DEAD CENTER
Top Dead Center (TDC)-the highest point at which the
piston, piston speed is 0, and it starts moving down.
Bottom Dead Center (BDC) is the lowest point at the
crankcase side, piston speed is 0, and it starts moving up.

3. BORE / STROKE:
Bore - the inner diameter of the cylinder (D)

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Stroke – Distance travelled by the piston between TDC and
BDC (L)

4. CRANK ANGLE:
The crank angle is the angle formed by the center line of the crank
and the line passing through the center of the piston pin and
crankshaft in reference to TDC and BDC.

5. EXHAUST CAPACITY / DISPLACEMENT

The displaced volume by piston movement from BDC to TDC. Can
be calculated using the formula,
¿ π r 2 L= A=π rD2 L /4
D= cylinder bore diameter
r= cylinder bore radius
L= stroke
π = 3.14

6. COMBUSTION CHAMBER VOLUME The volume

of space between the cylinder head and the
piston at TDC is called “combustion chamber
volume”.

a. v = Combustion Chamber Volume

b. V = Displacement Volume
7. CYLINDER VOLUME: The cylinder volume is
the total sum of the piston displacement (stroke
volume) and combustion chamber volume.
= (V+v)
 8. COMPRESSION RATIO: The compression
ratio indicates to what extent the air-fuel
mixture is compressed when the piston is at
T.D.C. of the compression stroke.

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 V+v
Compression Ratio = = Cylinder Vol /
v
Combustion Chamber Vol

Range: For 2 stroke: 6-8:1

For 4 stroke: 9-12:1
Note: for Diesel engine (Compression ignition):
18-20:1
9. PISTON SPEED: While the engine is running,
the piston speed is 0 at TDC and BDC and 2L N LN
Piston Speed = =
fastest in the middle of the stroke. Therefore, 60 30
the piston speed is indicated by an average L = Stroke= distance travelled by
value of speeds. The piston reciprocates with piston between TDC and BDC
each turn of the crankshaft and therefore, the N= number of turns of crankshaft in rpm.
piston moves 2L per one turn. When the
crankshaft makes N turns, the piston moves
2LN. To indicate it in seconds, it is divided by
60.
10. PISTON CLEARANCE:
The space between the piston and the cylinder wall, which
is provided as necessary to prevent piston from seizing up
in the cylinder due to thermal expansion.

11. TORQUE:
The turning force exerted on rotating parts is called “torque”.
Motorcycles are driven by the torque of the crankshaft.
T = F x r ( Kg.m or N.m)
For torques in Gears A & B
TA = F x r
TB = F x 2r
TB > TA
❑
But RPM of Gear A = 2 π rN [2x faster than Gear B]
The greater the number of teeth, the greater the torque.
However the rotational speed is reduced by half.
12. HORSEPOWER (Unit of Power)
Horsepower: work rate done within a specific time.= work Power (PS) =
done/ time taken (work done / sec) [ Kg.m /sec] Work load /Time (sec)
[1PS = 75 Kgm/sec =
735.49 W]
Work load = Fx S
11 S= distance travelled by
crankpin per min. = 2 π rN
T
PS = F.S = ( )x
r
 T
PS = F.S =( ) x 2 π rN divided by 60 = >>
r
Kg.m/sec

2 π NT π NT
1 PS = = = 0.0014 NT
60 x 75 716
N in RPM; T in Kg.m

13. BORE/ STROKE on ENGINE PERFORMANCE
Engines of the same displacement vary in character
depending on “bore and stroke”.
• Short stroke engines. Stroke is smaller than bore
diameter.
• Square engines. Stroke and bore diameter are even.
• Long stroke engines. Stroke is larger than bore
diameter.
Compared with a long stroke engine, the
square or short stroke type is easy to raise
the engine speed and develop high power. If
the engine speeds are the same, the piston
speed is slower and friction resistance can
also be reduced. Among other merits are the
lower overall height and compact design.
Therefore, the square type and short stroke
engines are dominant.

BASIC OPERATION OF FOUR STROKE ENGINE

ENGINE ACTION INTAKE/EXHAUST VALVE TIMING
INTAKE STROKE:
piston moves down,
combustion chamber pressure becomes
negative and the intake valve opens
fresh charge of mixture flows into the
chamber from the carburetor.

Actually, to increase the intake efficiency,

the intake valve opens slightly before the
piston reaches TDC and closes when the
piston starts up from BDC such that the
valve remains open longer and more
mixture is drawn in.

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 COMPRESSION:
piston moves up, intake vale closes at the
same time exhaust valve closes, mixture is
combustion chamber is compressed until
piston is at TDC the mixtures is highly
explosive, it will burn quickly.

EXPLOSION:
before end of compression stroke, spark
plug fires and ignites the compressed
mixture, mixture explodes and combustion
pressure forces the piston down,
thus, rotating the crankshaft via the
connecting rod.

EXHAUST STROKE:
before the piston moves down to BDC,
exhaust valve opens and burnt gases begin to
go out.
As the piston starts up from BDC, it forces out
the remaining gases.
After the piston starts going down from TDC,
the exhaust valve closes, and another fresh
mixture begins to flow in.

ENGINE CONSTRUCTION

DESCRIPTION FUNCTION
Upper - Forms the combustion chamber. Radiates heat.
- Cylinder head - Exchanges and burns gas. Radiates heat
- Cylinder
Internal Compresses mixture. Receives force of explosion. Opens and closes ports.
- Piston Seals between piston and cylinder
- Piston Ring
- Piston Pin Joins piston to connecting rod.
- Connecting
Rod & bearing Connecting piston and crankshaft.
- Crankshaft
Converts up-down movement of piston to rotational movement
Bottom Provides primary compression. Takes in mixture to be sent to cylinder

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 - Crankcase

Cylinder Head:
- Cooling
- Forming the combustion chamber
- Fitted with Spark plug

Cylinder:
- Exchanging and burning gas
- Having ports ( for 2 stroke engine)
- Having piston reciprocating inside
- Cooling

Piston:
- Compressing air/gas mixture
- Receiving force of explosion
- Opening and Closing ports ( for 2 strokes)
Piston Ring:
- Sealing
- Conducting piston heat to cylinder
Piston pin:
- Fixes piston to small end of connecting
rod
Connecting Rod & bearing:
- Connecting rod connects piston & crankshaft
- Bearing smoothes rotational movement

Crankshaft (Crank assembly):

- Converts up-down movement of piston to
rotational movement
- Smoothes rotational movement

Crankcase:
- Provides primary compression ( for 2 stroke)
- Contains the lube oil to be pumped or splashed
by rotating connecting rod to lubricate moving
parts

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VALVE: 2 Valves: intake and exhaust
- Controls the flow of fresh gas mixture and burnt
gases
- Makes a good seal with the valve seat
- Sturdy material, made of nickel-chrome steel

Valve Spring
- Presses the valve against the valve seat
- Ensures stable operation of valve at high speed
- 2 springs of variable pitch to prevent natural
oscillation and thus prevent valve surging.

Valve Clearance:
- Clearance provided between the rocker arm
and the end of valve stem.
- To compensate the thermal expansion of the
valve due to high temperature of the engine.
- Adjusted by turning the adjustment screw
- Note: MC V-clearance specs provided by the
manual.

Chain Tensioner
- Maintains the proper chain tension
- Stretching /tightening of chain due to
variations in engine speed, may cause
incorrect timing and the chain becomes noisy.

15
Valve Guide & Steam seals
- Guides the valve
- Lube oil flows into the combustion chamber &
be burned
- Stem seal keeps oil consumption to minimum.

ENGINE FUEL SYSTEM

Types:
1. Carbureted – using carburetor in mixing air and gasoline (atomized) to form a vaporized mixture
ready to be supplied to the engine.
2. Direct Fuel Injected – atomized fuel is directly injected to the throttle body to mix with the entering
air and form a mixture ready for engine consumption.

CARBURETOR:
Functions:
 Atomization of fuel – to facilitate good mixing of air and fuel.
 Control of mixing ratio – mixing ratio varies according to the need of the
engine’s operating conditions.
 Control of engine power – the supply of mixture also regulates the power
(speed RPM and torque) of the engine
Principles of Carburetor:
1. Venturi Effect: similar with the spraying; that is, an air compressed and
expanded with the increase of air velocity, a negative pressure or vacuum is
created at the point where air is expanded at higher velocity.

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 2. Combustion and Explosion: as characteristic of gasoline fuel or any
combustible substance.

Gasoline + Oxygen in air + mixed and shaken + ignited with fire=>>

Explosive combustion

Three conditions for

COMBUSTION:
1. Temperature
2. Oxygen (air)
3. Fuel Mixture Ratio
The air fuel ratio or the mixing ratio by weight. Such that, 15:1 means 15 g of air mixed
If any one of these is
with 1 g of fuel.
lacking, combustion
will not take place.

Mixture Ratio =

Note: To allow the gasoline to burn rapidly, it must be mixed with air in a specific ratio.
Otherwise too much gasoline or too much air, the mixture will not burn quickly.

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 Piston Throttle Valve and Variable
Venturi. Directly operated by throttle
cable. Varying the venturi diameter
regulates the mixture

Butterfly Throttle Valve and

Invariable Venturi
Throttle valve is directly operated
by cable
Positioned on engine side of the
fixed venturi.

Butterfly Throttle Valve and Variable

Venturi
A butterfly throttle valve & piston
valve in the venturi
Piston automatically moved up and
down by variations in the negative
pressure
Mixture flow is regulated by both
valves

Classification by Draft:
 Horizontal or side draft (used mainly for motorcycle)
 Down draft (mostly used for automobiles)

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VM Carburetor
Variable Mixture.
Forced variable venturi by the piston throttle valve varying
the venturi diameter.
The float chamber is positioned under the throttle valve,
and the fuel passage is divided into the pilot circuit (slow
circuit) and the main circuit.

SU or CV Carburetor
Constant velocity. Venturi diameter varies so that a
constant velocity mixture flow be maintained. The piston
valve automatically opened or closed by the negative
pressure in the intake system
SU used of 4 strokes engines and ensures smooth running
with better fuel economy

VM: its construction mainly consists of three (3) systems

1. Mixing chamber system: main unit of the carburetor, made up of
individual parts of air and fuel system. These control the fuel and air then
mix to produce the correct fuel-air mixture required by the engine.
2. Float Chamber system: Fuel is kept at a certain level to provide
consistent fuel flow.
3. Starting system (Starter Choke): an independent system to provide
richer mixture for need of starting cold engine.

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Component Part
Mixing Chamber System
1.Throttle Valve Float Chamber
2. Pilot Air Jet 13. Float bowl
3. Main Jet 14. Float
4. Jet Needle 15. Float valve
5. Needle Jet
6. Pilot Jet Starting System
7. By Pass Port 18. Starter plunger
8. Pilot Outlet 19. Fuel jet
9. Main Air Jet 20. Starter pipe
10. Pilot Air Jet 21. Starter air hole
11. Pilot Screw
12. Air bleed hole
16. Cut away
17. Venturi section

SU Carburetor

1. Spring 8. Main Jet (MJ)

2. Diaphragm 9. Pilot Screw (PS)
3. Piston valve 10. Pilot Air Jet (PAJ)
4. Jet Needle (JN) 11. Pilot Outlet (PO)
5. Main Air Jet (MAJ) 12. By Pass Port (BP)
6. Float 13. Throttle valve
7. Needle Jet (NJ) 14. Pilot Jet (PJ)

FUNDAMENTAL KNOWLEDGE: On Carburetor

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1. Bore:
BORE Diameter: Venturi bore, the bore
diameter of carburetor in mm, Ex. BS26

2. M/J (main Jet)

Main jet: controls the flow of fuel in the main
system at medium-speed and high speed. MJ
Number: Flow rate of fuel, ex. # 122.5 Large
No. = large flow rate of fuel Small No. = Small
flow rate of fuel

3. P/J (Pilot Jet)

Controls the flow rate of fuel in the pilot system
at low speed and medium speed.
PJ Number = Flow rate of fuel
Large No. = large flow rate of fuel
Small No. = Small flow rate of fuel.

4. Jet needle
Controls the quantity of fuel-air mixture discharged
from the needle taper section.

5. Needle jet:
Controls the quantity of fuel-air mixture
discharged from the gap between the needle
jet and the jet needle. Atomization of gasoline.

21
6. Diaphram & Spring
Activated by the difference between the
atmospheric pressure and the intake negative
pressure to control the quantity of air intake. A
jet needle is mounted to the center of the
piston valve.

7. Pilot air jet

Controls the flow rate of air in the pilot system
at idling to low speed. Quantity of air is
adjusted at the pilot air jet. Ex. # 127.5

8. Main Air Jet

Controls the quantity of air in the main fuel-air
mixture system at medium speed and high
speed. Controls the quantity of air to be fed to
the needle jet,. Allowing easy mixing with
gasoline sucked up through the main jet. Ex. #
70

9. Pilot screw
Controls the quantity of fuel-air mixture
discharged through the pilot outlet. Ex. #.0
(return speed)

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 FUNDAMENTAL KNOWLEDGE: On Carburetor
1. Bore:
BORE Diameter: Venturi bore, the bore
diameter of carburetor in mm, Ex. BS26

2. M/J (main Jet)

Main jet: controls the flow of fuel in the main
system at medium-speed and high speed. MJ
Number: Flow rate of fuel, ex. # 122.5 Large
No. = large flow rate of fuel Small No. = Small
flow rate of fuel

3. P/J (Pilot Jet)

Controls the flow rate of fuel in the pilot system
at low speed and medium speed.
PJ Number = Flow rate of fuel
Large No. = large flow rate of fuel
Small No. = Small flow rate of fuel.

4. Jet needle
Controls the quantity of fuel-air mixture discharged
from the needle taper section.

5. Needle jet:
Controls the quantity of fuel-air mixture discharged
from the gap between the needle jet and the jet
needle. Atomization of gasoline.

23
6. DiaGhram & Spring
Activated by the difference between the
atmospheric pressure and the intake negative
pressure to control the quantity of air intake. A
jet needle is mounted to the center of the
piston valve.

7. Pilot air jet

Controls the flow rate of air in the pilot system
at idling to low speed. Quantity of air is
adjusted at the pilot air jet. Ex. # 127.5

8. Main Air Jet

Controls the quantity of air in the main fuel-air
mixture system at medium speed and high
speed. Controls the quantity of air to be fed to
the needle jet,. Allowing easy mixing with
gasoline sucked up through the main jet. Ex. #
70

9. Pilot screw

Controls the quantity of fuel-air mixture

discharged through the pilot outlet. Ex. #.0
(return speed)

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Problem and inspection/adjustments of float system.
Overflow and fuel level variation may occur if there is a problem with the float system.

Overflow.
Overflow occurs when more fuel than the specified quantity flows into the
float chamber, This causes the fuel level to rise excessively until it is
discharged through the overflow pipe. If operation is continued in this state,
the mixture ratio becomes too rich and cause engine running problems, The
cause may be a punctured or damaged float, improper fuel level setting or
the needle valve cannot fully close due to foreign particles blocking the valve
seat area.

Float

Puncture Replacement
Improper operation (corrosion at the bending portion of the arm and pin section) Correction &
cleaning
Backlash of the arm and pin  adjustment of the arm
Deformation  Replacement
Too high fuel level  Adjustment of float lip

Needle Valve
Replacement of Set:
Clogging of dirt  Cleaning
Wear and flaw of needle  Replacement
Wear and flaw of valve seat  Replacement
Breakage of needle spring  Replacement

Deterioration and breakage of packing  Replacement

Inspection and adjustment of fuel level

The fuel level height is defined as the distance in mm from the center of the main bore depending on
the engine model and rarely fails during operation. If replacement of parts is performed, use the
following procedure to perform inspection and adjustment.

Method of inspection and adjustment

A fuel level gauge must be attached to the carburetor to properly measure the fuel-level height. The fuel
level height is generally determined by a standard measurement of the height of the float or float arm.
Turn the mixing chamber body upside down after removing the float chamber body and packing.
After raising the float and checking that the needle valve is completely closed, lower the float gradually
to position the float lip in contact with the needle, and measure the float height from the chamber joint
surface (Dimension H)
For the independent float type, measure the height of the float arm.
If the height is deviated from the standard value, adjust it by bending the lip of the float arm.

25
 Inspection of actual fuel level
With a fuel level measuring device mounted to the
carburetor, measure the actual fuel level by setting a fuel
level gauge.
Mount a special tool (Fuel level gauge) to the carburetor
drain.
Set the position of the fuel cock level to “PRI” or “ON” and
loosen the drain screw.
Align the fuel level gauge with the mixing chamber body and
read the fuel level from the float chamber joint surface as a
standard.

Idle adjustment
1. Adjust the throttle cable free play at the throttle grip to 3-7 mm
2. Set the air screw to the specified setting
3. Start the engine and warm up sufficiently – Attach an engine tachometer.
4. Set the idling speed to a value a little higher than the specified value using the throttle
stop screw. (approx 100 rpm)
5. Turn the air screw in and out ¼ to ½ to check for idle speed change. If no change is
found, set the screw to specification as described in b.
6. Set the idle speed specification
7. Finally, rev the engine two or three times and check to for a stable idle and smooth
rotation of the throttle when opening gradually.

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Other inspection items
Mounting of carburetor
- Tighten the mounting portions securely at both the engine aside and the air cleaner side
si that air leakage (suction of air) does not occur.
- Mount the carburetor vertically. If not, the fuel level fluctuates.

 Inspection of choke device (starter)

- Cable type: Cable slacks must be correct, Set the slack to approximately 1 mm.
- Level type: for a type in which multiple carburetors are connected with rods, operate
the lever to see if the right and left starter plungers operated evenly. Check to see if
both the right and left plungers are opened evenly when fully opened, and check to see
if the plungers float without returning completely when they are returned.

 Inspection of air vent pipe.

Check to see if the air vent pipe is clogged, bent or caught somewhere. If the pipe is clogged or bent,
flow of fuel is not proper, resulting in a lean fuel/air mixture.

 Inspection of vacuum pipe.

If a negative pressure cock (automatic cock) is used as a fuel cock, a vacuum pipe is connected to the
carburetor or the manifold section, Check for damage, bending and catching of the hose and mount it
securely so that air leakage or an automatic cock malfunction does not occur.

 Inspection of delivery pipe.

If a discharge nozzle for auto-lube oil is provided in the carburetor, mount the delivery pipe from the oil
pump securely so that oil leakage or suction of air does not occur.

FUEL TANK
1. Necessity for fuel tank
 To store fuel safety
 To supply fuel when necessary

2. Structure of fuel tank

 Tank cap
 Filter tube
 Fuel cock
 Damper

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3. Types of fuel tanks
Classification by material
 Steel - - - - Business: Motorcycle scooter
 Aluminum - - - Competition motorcycle

4. Function of filler tube

To prevent gasoline from flowing out when fuel tank
is full (Gasoline expands when warmed up)

FUEL TANK CAP

1. Necessity for fuel tank cap
 To seal tank inlet
 To protect fuel from dust and water
 To admit air, and allow fuel
to breathe (breather)
 To prevent gasoline leakage if
motorcycle turns over.

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2. Structure of tank cap
 Filter
 Check valve

3. Operation of breathing valve (with check ball)

When tank cap is in normal position: Opening of air passage 
air bleeding
When tank cap is sideways or in the upside down position:
Closing of air passage  To prevent reverse flow of fuel

Types of tank caps

 Breather pipe type - - For motocross type motorcycle
 Normal type - - Small motorcycle
 Check valve type (with check ball) - - Big size motorcycle

FUEL COCK

A fuel cock is used under the fuel tank for the passage of fuel. It not only controls the flow of fuel form
the fuel tank to the carburetor but also screens out dust particles. Fuel cocks come in two types as
described below.

Standard type of cock

This is manually operated cock. Switching of the cock lever will cut off or permit the flow of fuel. There
are three passages in the cock body. Inside the cock lever, there is a passage which can connect the
incoming

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 Lever position and passage of fuel
ON position
Long level pipe  Opening A  Passage inside lever  Opening
B  Filter cup  Filer Fuel pipe  Carburetor (Select this
position for normal riding)

RES Position
Long lever  Opening C  Passage inside lever  Opening B 
Filter cup  Filter Fuel pipe  Carburetor (Select this position
for riding on reserve fuel)

OFF (STOP) Position

Lever pipe  Opening A  Passage inside lever is closed and
not connected to Opening B (Select this position for long-term
stopping.)

Vacuum type cock

This is an automatic cock that is opened automatically when the engine starts or stops. Suction
produced in the cylinder is used to operate the cock. There are four passages in the cock body. Inside
the cock lever, there is a passage which connect the incoming and outgoing passages. The lever has
three positions; ON RES and PRI (priming, direct). This cock has diaphragms which move with suction
from the engine. When the engine starts, the diaphragms detect suction and open the fuel passage.
When the engine stops, they operate to cut off the passage.

Lever position and passage of fuel

ON Position
Long lever pipe  Opening A  Passage inside lever  Opening B  Valve  Filter cup  Filter 
Carburetor (Select this position for riding)

RES Position
Short lever pipe  Opening C  Passage inside lever  Opening B  Valve  Filter cup  Filter 
Carburetor (Select this position for riding on reserve fuel)

PRI Position
Short lever pipe  Opening C  Passage inside lever  Opening D  Filter cup  Filter  Carburetor
Fuel does not pass the diaphragm valve but flows directly to filter cup

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Operation of fuel cock
Necessity of fuel cock
 ON: allows gasoline to flow to carburetor
 OFF: Stops gasoline from flowing to carburetor
 Filter: Filters foreign matter from gasoline

Structure of fuel cock

 Cock lever
 Cock body
 Rubber seal
 Filter

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Operation of fuel cock
Lever position/Fuel flow

LEVEL Fuel flow

ON CEF Carburetor
RES DEF
CEF
OFF

DEF

Type of fuel cock

 Manual type
 Flat seal type
 Coned seal (Tapered) type
 Vacuum fuel cock type

Operation of vacuum fuel cock

Structure of vacuum fuel cock

Operation
E/G OFF
Valve is pushed against the seat by a spring.
Valve is closed

E/G ON
Vacuum is stronger than spring force.
Valve is opened.

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 PRI
Gasoline passes fuel cock directly without going
through vacuum fuel cock.

FUEL
Since internal combustion engines are heat engines, fuel must have high caloric power and must not
emit pollution gases. The fuel used for motorcycle engines should be low cost and safe to handle, since
it is used by the general public.

1. Gasoline
Gasoline is clear and colorless with a distinctive smell, has high volatility and consists essentially of a
blend of many types of hydrocarbons. In general, it features a specific gravity of 0.72~0.77, a lower
caloric value of 10,400 ~ 11,000 kcal/kg, an octane rating of 85~ 100, and ignition point of 500°C
(approx.) and a flash point of -25°C or more, making it an extremely flammable fluid.

1. Octane rating Item No. 1(leaded No.2 (Un-leaded

The octane number indicates anti-knock gasoline) gasoline)
performance. The higher the octane rating, Octane rating 95 or 97 85 or more 86 ~
the greater the resistance to knocking. (Research) 97~ 91
98
Lead content 0.16 0.001 or less
2. Flash point ml/L
The flash point is the lowest temperature at which vapors from a volatile liquid will ignite momentarily
upon the application o a small flame under specified conditions. Gasoline has a low flash point, so it
must be stored and handled with care according to regulations.

3. Gasoline additives
Various additives are used in gasoline to improve the quality of the gasoline. Representative of these is
the octane number enhancer to prevent abnormal combustion. As an octane number enhancer,
tetraethyl lead (TEL) , etc. is widely used. Currently, from the viewpoint of reducing atmospheric
pollution, the use of tetraethyl lead, etc. is decreasing and non-leaded is being used.

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 4. Notice about gasoline handling
o Do not leave containers of gasoline open and unattended.
o Keep flames away from gasoline.
o Store gasoline in a location with good ventilation
o Provide a fire extinguisher that is effective in extinguishing gasoline fires.

5. Gasoline production method

Gasoline production methods include the distillation method and the decomposition method. The
distillation method involves distilling the gasoline from crude oil. The decomposition method involves
subjecting heavy oil such as gas oil and heavy fuel oil to thermal cracking, or to catalytic cracking by a
catalyst, to transform the oil into a substance with a low boiling point, which is them distilled again to
produce gasoline. In these cases, the product of the former process is direct distillation gasoline and the
product of the latter process is cracked gasoline.

2. Light (Diesel) Oil

Gas oil s a petroleum distillate obtained after gasoline and kerosene are collected, It has a specific
gravity of 0.84~ 0.9, a boiling range of 200 °C ~ 250°C or more. Its color is a yellow or light brown, Gas oil
has better ignitability than gasoline, it is used in high speed diesel engines.
Item No.1 No.2 No.3 Special No.3
Liquidity point °C -5 °C or less -10 °C or less - 20 °C or less - 30 °C or less
Cetane number, cetane index 50 or more 45 or more 40 or more 42 or more

1. Cetane number and cetane index

Both cetane number and index indicate the ignitability of fuel. The greater the number or
index, the higher the ignitability.
2. Ignition point
The ignition point is the lowest temperature at which a fuel ignites itself when the fuel
temperature is raised.

Item No. 1 No. 2 No. 3 No. 4 No. R No. C

Vapor pressure (40°C( (kg. cm2) 15.8 or less 15.8 or less 12.7 or less 5.3 or less 15.6 or less 15.6 or less
Main purposes For industrial use, automobiles, For industrial use, automobiles, For household For household use
other business, and other use (General) (Winter or cold areas)

3. LP gas
Liquefied petroleum gas is obtained from natural gas coming from wells and also form gas generated in
the petroleum refining process at the refinery. It is a hydrocarbon which is easily liquefied by applying
pressure at normal temperatures.
Properties: Liquid specific gravity, 0.51~0.58; gas specific gravity, 1.45~ 2.07; lower caloric value,
10.920~ 11,080 kcal/kg; octane rating, 94~100, ignition point, 440~540°C; boiling point, -42°C~ - 0.5°C

34
 INFORMATION SHEET 1.1.3
ON FUEL INJECTION
(PGM-FI Fuel Injection)

After reading this INFORMATION SHEET, YOU MUST be able to :

1. Explain the working principles of the different sensors in a Fuel Injected engine
fuel system;
2. Explain the advantages of the FI Fuel system.
3. Explain the indicators of the Malfunction Indicators Lamp (MIL) in the trouble
shooting.

Fuel efficient

Easy to start
performance

Environment
friendly
Better
The PGM-FI Advantage:
The fuel particles are smaller and homogenized    
Fuel is supplied to the combustion chamber more    
constantly and effectively by the fuel injector.

PGM-FI system is equipped with sensors that provide    

information to the ECM for very accurate fuel supply in
every condition

Honda introduced in the market the programmed Fuel Injection (PGM-FI) Motorcycle
since 1982. This fuel system is meant to optimize the control of air-fuel mixture and
ignition timing to always maintain ideal combustion (15:1 air/fuel ratio), the ECM
monitors parameters such as the engine speed, intake manifold pressure, throttle
position, and temperature to achieve keen response and smooth output across all the
speed range, it also enables reduced fuel consumption, fuel toxic substances in the
exhaust gas.

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Malfunction indicator lamp (MIL) helps to diagnose the trouble easily.

SENSORS AND ITS FUNCTION

Abbreviation Full Term Sensor Functions
ECM Engine control module Acts a brain of the system
MIL Malfunction Indicator Lamp Error blink pattern located at the meter
panel
DLC Data Link Connector Port where SCS Connector is inserted.
SCS Connector Service Check Short ECM determines the amount of
Connector injection at start up due to engine
coolant temperature
ECT / EOT Engine Coolant/Oil Fuel injection volume correction due to
Sensor Temperature vehicle speed.
VS Sensor Vehicle Speed Sensor The ECM determines the fuel injection
timing detecting the engine speed with
this signal.
CKP Sensor Crankshaft Position Sensor The ECM determines the fuel injection
timing detecting the engine speed with
this signal.
TP Sensor Throttle Position Sensor The ECM determines the following with
this signal:
 To determine the basic amount of
injector based upon the throttle
opening.
 To switch between the intake air
pressure and throttle opening
 To determine the throttle opening
O2 Sensor Oxygen Sensor When there is difference in oxygen
concentration at an activation
temperature, electromotive force is
generated, the ECM performs feedback
compensation of air-fuel ratio with this
signal.
IAT Sensor Intake Air Temperature Fuel injection volume correction due to
Sensor intake air temperature
MAP Sensor Manifold Absolute Pressure Fuel injection volume correction due to
Sensor manifold absolute pressure.
Bank Angle Bank Angle Sensor A bank angle sensor is installed so that
the ECM stops the injector; ignition coil
and fuel pump to forcibly stop the
engine when the vehicle tilts beyond a
preset angle.

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 MIL Function Failure Symptom/Fail-safe function
1 MAP Sensor malfunction  Engine operate normally
 Loose or poor contact or the MAP sensor
connector.
 MAP sensor or its circuit malfunctions.
7 ECT Sensor malfunction  Hard start at low temperature
 Loose or poor contact of the ECT sensor  Cooling fan turns on
connector.
 ECT sensor or its circuit malfunctions.
8 TP Sensor malfunction  Poor engine acceleration
 Loose or poor contact of the TP sensor connector
 TP sensor or its circuit malfunctions.
9 IAT Sensor malfunction  Engine operates normally
 Loose or poor contact of the IAT sensor
connector
 IAT sensor or its circuit malfunctions.
12 Injector malfunction  Engine does not start.
 Loose or poor contact of the injector  Injector, fuel pump and ignition
 ECT sensor or its circuit malfunctions. coil shut down.
21 O2 Sensor malfunction  Engine operates normally.
 Loose or poor contact of the O2sensor connector
 O2 sensor or its circuit malfunction
29 IACV malfunction  Engine stall, hard to start, rough
 Loose or poor contact of the IACV connector idling.
 IACV or its circuit malfunctions.
54 Bank Angle Sensor malfunction  Engine operates normally.
 Loose or poor contact of the IACV sensor  Bank angle sensor stops the
connector control.
 IACV or its circuit malfunctions.
MIL CODE INDEX

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