33.6 Test connections and data

Sanwa tester - K-ohms range

Kowa tester- 100 ohms range

°° - infinite resistance (no continuity)

Electrical system 9»23

Coolant SS^fSS, rtimUgnml

temperature "ff"' switch ^^y

pondP'

- . mnt-r ignmon cons

CB500R German market model

T, V. W, X and Y modals

Ignition (main) switch

^Fan JZL, Ignition coils SMtch motor ^^^p^

Coolant Rear brake Tumtttftal tamparatura tight swHch ^_ay

sonder

Puts* ganarmtor "ST

OO0

Neutral switch

CB500 T, V, W, SW, X, SX, Y, SY models

REF»1

^Reference

Tools and Workshop Tips

REF«2

MOT Test Checks

REF-27

• 

  

  Building up a tool kit and equipping your workshop • Using tools

• Understanding bearing, seal, fastener and chain sizes and markings

• Repair techniques

• A guide to the UK MOT test • Which items are tested • How to prepare your motorcycle for the test and perform a pre-test check

Security

REF-20

• Locks and chains

• U-locks • Disc locks

• Alarms and immobilisers

• Security marking systems • Tips on how to prevent bike theft

Storage

REF-32

• How to prepare your motorcycle for going into storage and protect essential systems • How to get the motorcycle back on the road

Lubricants and fluids

REF-23

• Engine oils

• Transmission (gear) oils

• Coolant/anti-freeze

• Fork oils and suspension fluids • Brake/clutch fluids

• Spray lubes, degreasers and solvents

Fault Finding	■ 77 VI
	A
w kIIS^H
Mj. J ^H

REF-35

• Common faults and their likely causes • How to check engine cylinder compression • How to make electrical tests and use test meters

Technical Terms Explained

REF«49

Conversion Factors

2>4- Nw* x 0.738

REF*26

• Formulae for conversion of the metric (SI) units used throughout the manual into Imperial measures

Index

• Component names, technical terms and common abbreviations explained

REF-53

REF-2 Tools and Workshop Tips

Buying tools

A toolKit is a fundamental requirement for servicing and repairing a motorcycle. Although there will be an initial expense in building up enough tools for servicing, this will soon be offset by the savings made by doing the job yourself. As experience and confidence grow, additional tools can be added to enable the repair and overhaul of the motorcycle. Many of the specialist tools are expensive and not often used so it may be preferable to hire them, or for a group of friends or motorcycle club to join in the purchase.

As a rule, it is better to buy more expensive, good quality tools. Cheaper tools are likely to wear out faster and need to be renewed more often, nullifying the original saving.

A Warning: To avoid the risk of a poor quality tool breaking in use, causing injury or damage to the component being worked on, always aim to purchase tools which meet the relevant national safety standards.

The following lists of tools do not represent the manufacturer's service tools, but serve as a guide to help the owner decide which tools are needed for this level of work. In addition, items such as an electric drill, hacksaw, files, soldering iron and a workbench equipped with a vice, may be needed. Although not classed as tools, a selection of bolts, screws, nuts, washers and pieces of tubing always come in useful.

For more information about tools, refer to the Haynes Motorcycle Workshop Practice TechBook (Bk. No. 3470).

Manufacturer's service tools

Inevitably certain tasks require the use of a service tool. Where possible an alternative tool or method of approach is recommended, but sometimes there Is no option if personal injury or damage to the component is to be avoided. Where required, service tools are referred to in the relevant procedure.

Service tools can usually only be purchased from a motorcycle dealer and are identified by a part number. Some of the commonly-used tools, such as rotor pullers, are available in aftermarket form from mail-order motorcycle tool and accessory suppliers.

Maintenance and minor repair tools

Set of flat-bladed	6 Set of Ton keys or bits	11 Cable oiler clamp	16 Calibrated syringe,	21 Straight-edge and
screwdrivers	7 Pliers, cutters and	12 Feeler gauges	measuring vessel and	steel rule
Set of Phillips head	self-locking grips	13 Spark plug gap	funnel	22 Continuity tester
screwdnvers	(Mole grips)	measuring tool	17 Oil filter adapters	23 Battery charger
Combination open-end	8 Adjustable spanners	14 Spark plug spanner or	18 Oil drainer can or	24 Hydrometer (for battery
and ring spanners	9 C-spanners	deep plug sockets	tray	specific gravity check)
Socket set (3/8 inch	10 Tread depth gauge and	15 Wire brush and	19 Pump type oil can	25 Anti-freeze tester (for
or 1/2 inch drive)	tyre pressure gauge	emery paper	20 Grease gun	liquid-cooled engines)
Set of Allen keys or bits

Tools and Workshop Tips ref-3

Repair and overhaul tools

1. Torque wrench (small and mid-ranges)

2. Conventional, plastic or soft-faced hammers

3. Impact driver set

4. Vernier gauge 7 Selection of pullers

5. Circlip pliers (internal and 8 Breaker bars external, or combination) 9 Chain breaking/

6. Set of cold chisels riveting tool set and punches

10. Wire stripper and crimper tool

11. Multimeter (measures amps, volts and ohms)

12. Stroboscope (for dynamic timing checks)

13. Hose clamp (wingnut type shown)

14. Clutch holding tool

15. One-man brake/clutch bleeder kit

Specialist tools

_ttttft

1. Micrometers (external type)

2. Telescoping gauges

3. Dial gauge

4. Cylinder compression gauge

5. Vacuum gauges (left) or manometer (right)

6. Oil pressure gauge

7. Plastigauge kit

8. Valve spring compressor (4-stroke engines)

9. Piston pin drawbolt tool

10. Piston ring removal and 13 Stud extractor installation tool 14 Screw extractor set

11. Piston ring clamp 15 Bearing driver set

12. Cylinder bore hone (stone type shown)

ref.4 Tools and Workshop Tips