Extensive Service: BIG TWINS

PRE-SERVICE INSPECTION

Record customer concerns / reported faults

Record warning lights/messages

Check motorcycle for existing damage

Check engine oil level before service

Check tyre pressures before service

Check motorcycle starting condition

Listen for abnormal engine/mechanical noises

Initial electrical function

Check Initial diagnostic scan

Record current and historic fault codes

Check service history where available

Identify aftermarket modifications/accessories

ENGINE CONDITION

Check engine starting

Check cold idle

Check hot idle

Check throttle response

Listen for bottom-end noise

Check for abnormal cam/valvetrain noise

Check for exhaust smoke

Inspect engine mounting points

Check engine mounting fasteners

Check visible wiring/sensors around engine

Check engine temperature operation

Compression test if condition/history warrants

Record compression: Front ______ / Rear ______

Leak-down test if required

Record results: Front ______% / Rear ______%

ENGINE — OIL & LUBRICATION

Warm engine before draining where appropriate

Check for excessive engine vibration/noise

Inspect engine for oil leaks

Inspect rocker box area for leakage

Inspect pushrod tube seals — where applicable

Inspect cam cover area

Inspect crankcase joints

Inspect oil cooler and lines — where fitted

Inspect crankcase breather system

Drain engine oil

Inspect drained oil for contamination

Inspect oil drain plug/thread

Replace drain plug O-ring/seal as required

Replace engine oil filter

Refill with correct specification engine oil

Confirm correct engine oil level

COOLING SYSTEM — WHERE APPLICABLE

Check coolant level

Check coolant condition

Check coolant service interval / Replace if due.

Inspect radiator Inspect radiator hoses

Check system for coolant leaks

Clean radiator externally as required

Check hose clamps Inspect water pump area

Check cooling fans / operation

Check temperature sensor operation

PRIMARY DRIVE

Drain primary fluid

Inspect drained fluid for contamination/metal

Replace primary fluid

Inspect primary drain plug

Inspect primary drain plug

Replace drain plug seal/O-ring as required

Inspect primary cover for leaks

Inspect primary gasket/seals

Inspect primary chain condition where accessible

Check primary chain tension — where applicable

Check compensator operation/noise

Check clutch operation

Check clutch adjustment

Check clutch cable — cable models

Check hydraulic clutch fluid/system — where fitted

Inspect clutch components where service interval requires

TRANSMISSION

Drain transmission oil

Inspect oil for contamination/metal

Replace transmission oil

Inspect drain plug/magnet

Replace drain plug seal/O-ring as required

Check transmission for leaks

Inspect transmission seals externally

Check gear selection

Check neutral selection

Lubricate linkage where appropriate

Check linkage fasteners

Check for abnormal transmission noise

AIR INTAKE

Remove air cleaner

Inspect air filter

Clean serviceable filter as appropriate

Replace filter if required

Inspect air cleaner housing/backplate

Inspect intake for contamination

Inspect breather system

Check breather hoses

Inspect intake manifold

Check intake manifold seals

Check throttle body cleanliness

Clean throttle body if required

FUEL SYSTEM

Inspect fuel tank

Inspect fuel cap/seal

Inspect fuel lines

Inspect fuel fittings/connections

Check system for fuel leaks

Check fuel pump operation

Inspect injector connections

Check fuel pump operation

Check fuel pressure if required Inspect throttle cables — where fitted

Check throttle free play

Confirm throttle snaps closed correctly

IGNITION

Remove / Inspect spark plug condition

Record abnormal plug deposits

Check spark plug gap where applicable

Replace spark plugs as required

Inspect ignition coils

Inspect coil connections

Inspect plug leads — where fitted

Check ignition-related diagnostic codes

FINAL DRIVE BELT

Thoroughly clean/inspect drive belt Inspect belt teeth

Inspect belt edges

Check belt for cracks

Check belt for stone damage

Check belt for missing/damaged teeth

Check/Record belt tension

Check belt alignment

Inspect front pulley Inspect rear pulley

Inspect pulley teeth

Check pulley fasteners

Inspect belt guards

Check rear wheel alignment

FRONT BRAKE SYSTEM

Measure front brake pads: ______ mm

Inspect pads for uneven wear

Inspect front disc(s)

Measure disc thickness if required: ______ mm

Check disc runout/warping symptoms

Inspect caliper(s)

Check caliper pistons where accessible

Check caliper mounting fasteners

Inspect brake hoses

Inspect hose fittings

Check master cylinder

Check reservoir

Check brake fluid level

Check brake fluid condition

Check brake fluid replacement interval

Replace/bleed brake fluid

Check brake lever operation

Check brake lever pivot

Lubricate pivot where appropriate

Check front brake light switch

REAR BRAKE SYSTEM

Measure rear brake pads: ______ mm

Inspect pads for uneven wear

Inspect rear disc

Measure disc thickness if required: ______ mm

Check rear caliper

Check caliper mounting

Inspect rear brake hose Inspect fittings

Check rear master cylinder

Check reservoir

Check brake fluid level

Check brake fluid condition

Replace/bleed fluid

Check brake pedal adjustment

Check brake pedal pivot

Check rear brake light switch

ABS SYSTEM

Check ABS warning light sequence

Diagnostic scan ABS module

Check ABS fault codes

Inspect front/rear wheel speed sensor

Check sensor clearances where applicable

Inspect sensor rings

Inspect ABS wiring Inspect ABS hydraulic unit/connections

Confirm ABS operation during road test where safe

FRONT TYRE & WHEEL

Record front tyre make/model: __________________

Record tyre size: ___________

Record tyre date code: __________

Record pressure before adjustment: ______ PSI

Set pressure: ______ PSI

Record tread depth: ______ mm

Inspect centre tread / shoulders

Check for cracking / deformation

Check for punctures/repairs

Inspect valve/valve stem

Inspect rim for damage

Check wheel runout visually

Check front wheel bearings

Check spokes — where applicable

Check spoke tension — where applicable

Check front axle

Check axle fasteners

REAR TYRE & WHEEL

Record rear tyre make/model: __________________

Record tyre size: ___________

Record tyre date code: __________

Record pressure before adjustment: ______ PSI

Set pressure: ______ PSI

Record tread depth: ______ mm

Inspect centre tread / shoulders

Check for cracking / deformation

Check for punctures/repairs

Inspect valve/valve stem

Inspect rim for damage

Check wheel runout visually

Check rear wheel bearings

Check spokes — where applicable

Check spoke tension — where applicable Check rear axle

Check axle fasteners

STEERING HEAD

Raise/support front wheel where appropriate

Check steering head free movement

Check bearings for play/ notchiness

Check bearing adjustment – adjust if required

Lubricate/service bearings where service schedule requires

Inspect steering stem area

Check steering stops

Check lock-to-lock movement

Ensure cables/wiring don’t bind

FRONT SUSPENSION

Inspect fork tubes for damage/pitting

Inspect fork and dust seals

Check for fork oil leakage

Check fork operation

Check fork alignment

Check fork mounting fasteners

Check triple clamps

Check fork oil service interval

Replace fork oil if due/requested

Check electronic suspension — where fitted

REAR SUSPENSION

Inspect rear shock absorber(s)

Check for oil leakage

Check spring condition

Check shock bushes and mounting upper/lower

Check mounting fasteners

Check preload adjustment

Check electronic adjustment — where fitted

Inspect swingarm

Check swingarm bearings/play

Inspect suspension linkage — where applicable

HANDLEBARS & CONTROLS

Check handlebars & alignment

Check risers / riser bushes

Check handlebar fasteners

Inspect grips

Check heated grips — if fitted Check throttle operation

Check clutch lever

Check brake lever

Check switchgear

Check mirrors & mounting

Inspect control cables & routing

Lubricate applicable cables/pivots

FOOT CONTROLS

Check gear selector

Check shift linkage

Check rear brake pedal

Check rider footrests/floorboards

Check passenger footrests/floorboards

Check all fasteners

Lubricate pivots as required

BATTERY

Visual battery inspection

Check battery mounting

Check terminals and clean if required

Check terminal tightness

Battery resting voltage: ______ V Battery load/health test

Battery health: ______ %

Record test result: PASS / MONITOR / REPLACE

CHARGING & STARTING SYSTEM

Check starter operation

Check starter wiring

Check charging system

Charging voltage at idle: ______ V

Charging voltage raised RPM: ______ V

Check regulator/rectifier

Inspect charging connections

Check for charging-system fault codes

ELECTRICAL SYSTEM

Headlight low beam

Headlight high beam

Passing/flasher switch

Front indicators

Rear indicators

Hazard lights

Tail light

Number plate light

Horn Instrument cluster

Warning lamps

Fuel gauge

Switchgear Accessory socket/USB — if fitted

Heated grips — if fitted Heated seat — if fitted

Auxiliary lights — if fitted

ELECTRONIC SYSTEMS & DIAGNOSTICS

Full diagnostic system scan

ECM fault codes

BCM fault codes

ABS fault codes

Instrument fault codes

Security system fault codes

Other module codes

Record active codes

Record historic codes

Investigate relevant codes

Clear codes after repairs/service where appropriate

Re-scan after service

Check service reminder

Reset service reminder where applicable

SECURITY / KEY FOB

Check key/fob operation

Check security system

Check immobiliser

Check alarm — where fitted

Check fob battery condition – Replace if required

FRAME & CHASSIS

Inspect frame for damage

Inspect frame welds visually

Check engine mounts

Check major chassis fasteners

Check side stand mounting

Check side stand spring

Check side stand switch — where fitted

Check centre stand — where fitted

Check crash bars/highway bars

Check accessory mounting points

Inspect exhaust headers Inspect header flanges

Check exhaust seals for leakage Inspect mufflers

Check muffler mounts

Check muffler mounts

Check exhaust brackets

Check heat shields

Check exhaust fasteners

Inspect O2 sensor wiring

Check exhaust for abnormal movement

BODYWORK & EQUIPMENT

Check front guard

Check rear guard

Check side covers

Check seat condition

Check seat mounting

Check pillion seat — where fitted

Check windscreen

Check fairing

Check panniers and locks

Check top box — if fitted

Check luggage racks

Check crash protection

Check aftermarket accessories for security

TOURING MODEL ADDITIONAL CHECKS — WHERE FITTED

Check infotainment system

Check speakers/audio

Check navigation/GPS

Check cruise control

Check screen mechanisms

Check rider/passenger controls

Check electronic suspension features

FASTENER & SECURITY CHECK

Handlebar/risers

Front axle Rear axle

Brake calipers

Brake discs visually

Foot controls

Floorboards/footrests

Engine mounts

Exhaust system

Suspension mounting

Guards

Seat Luggage

Number plate

Accessories Visible critical fasteners

LUBRICATION

Clutch lever pivot

Brake lever pivot

Brake pedal pivot

Gear lever/linkage

Footrest pivots

Side stand pivot

Applicable cables

Other manufacturer-specified lubrication points

ROAD TEST

Cold starting satisfactory

Hot starting satisfactory

Idle satisfactory

Throttle response satisfactory

Engine performance satisfactory

Clutch engagement satisfactory

Gear selection satisfactory

Neutral selection satisfactory

Transmission operation satisfactory

Front brake performance

Rear brake performance ABS operation where safely testable

Steering satisfactory

Straight-line tracking

Front suspension operation

Rear suspension operation

Check wheel/tyre vibration

Check drivetrain vibration

Check abnormal engine noise

Check abnormal transmission noise

Check belt/drivetrain noise

Speedometer operation

Instruments Cruise control — where fitted

Final warning-light check

POST-ROAD-TEST INSPECTION

Check engine oil level

Check primary fluid

Check transmission oil

Check coolant — where applicable

Inspect engine for fresh leaks

Inspect primary for fresh leaks

Inspect transmission for fresh leaks

Inspect brake system

Recheck tyre pressures

Recheck belt

Final diagnostic scan

Confirm no relevant warning lights

FINAL QUALITY CONTROL

All service operations completed

All measurements recorded

All fluids confirmed

Drain plugs checked

Oil filter checked

Critical fasteners checked

Service reminder reset

Motorcycle wiped down/cleaned

Customer accessories accounted for Technician final inspection

Workshop quality-control inspection

CONDITION REPORT / KEY MEASUREMENTS

Front tyre: ______ PSI / ______ mm

Rear tyre: ______ PSI / ______ mm

Front pads: ______ mm

Rear pads: ______ mm

Front disc: ______ mm

Rear disc: ______ mm

Battery: ______ V / ______ %

Charging: ______ V

Compression Front: ______

Compression Rear: ______

POST SERVICE REPORT

POST SERVICE REPORT – ITEMS REQUIRE ATTENTION

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POST SERVICE REPORT – RECOMMENED/UPCOMING MAINTENCE