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| CYLINDER HEAD |
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| cylinder head (two stroke) |
[ head ]
In a two stroke engine this is a solid piece of metal which covers the top
of the barrel & contains a threaded hole for the spark plug |
| cylinder head (four stroke) |
[ head ]
In a four stroke engine the cylinder head is a major engine component containing
the valves & camshaft(s). Can be supplied as a bare casting with matching
cam caps (& usually the valves) or as a complete assembly including
the camshafts. Always specify exactly what you require when ordering. V-twin
& V-four engines have two cylinder heads - remember to specify which
head you need when ordering i.e. RH / LH for longitudinal crankshaft bikes
(e.g. Moto Guzzi 1100 California 750 Breva Griso) or front / rear for transverse
crankshaft bikes (e.g. Ducati 900SS Monster 600 620 750 900 / Suzuki TL1000S
TL1000R) |
| camshaft |
[ cam / cams ]
Shaft with machined ‘pear-shaped’ profiles (lobes). The shape
of the cam profiles determines the timing and duration of valve opening
within the cylinder head. Engines can use a single camshaft above (SOHC
= single overhead cam) or below (OHV = overhead valve) the cylinder head,
or twin camshafts (DOHC = double overhead cam) |
| inlet camshaft |
[ inlet cam ]
Determines the timing and duration of the inlet valves opening within the
cylinder head (DOHC engines) |
| exhaust camshaft |
[ exhaust cam / outlet cam ]
Determines the timing and duration of the exhaust valves opening within
the cylinder head (DOHC engines) |
| cam caps |
Secures the camshaft(s) to the cylinder head. Can be a set of individual
caps, or a larger single camshaft retaining plate. Either way, the cam caps
are usually cast with the cylinder head and then machined off, so ideally
they should be sold with a matching cylinder head |
| valves |
[ cylinder head valves ]
Remember to specify if you need a full set or individual inlet & exhaust
valves |
| rockers |
[ rocker arm ]
Operated by a camshaft, the rocker pivots to push open a valve or valves
within the cylinder head |
| cam bucket |
[ cam lifters ]
Bucket-shaped component situated between a camshaft profile and a valve |
|
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| ELECTRICAL & IGNITION |
 |
| CDI unit (carburettor bike) |
[ spark unit / black box / igniter unit / IC igniter / TR igniter / digital
igniter ]
This is the ‘brain’ of an electronic ignition system. It receives
engine speed information (usually from a pick-up sensor) and determines
when to ignite the fuel mixture. The term ‘CDI’ (Capacitor Discharge
Ignition) is a good catch-all term as it is widely used by the breakers,
even for igniter units that use transistors rather than capacitors (e.g.
XTZ750 Super Tenere / XJ900 58L) |
| ECU (fuel injection bike) |
[ Electronic Control Unit / electronic brain / black box ]
More sophisticated than a CDI unit (which only determines ignition timing),
the ECU controls all the bike’s electrical systems (gathering information
from various sensors); manages fuel/air mixture and ignition timing etc
(e.g. Kawasaki ZX12R) |
| Crank sensor |
[ crank speed sensor ]
Reports rotational speed of the crankshaft to the ECU to determine ignition
timing (similar to a pick-up on a CDI-carburettor bike). Can also double
as an engine speed sensor (i.e. revs per minute) |
| Camshaft sensor |
[ cam sensor ]
Reports camshaft position to the ECU to determine ignition timing (similar
to a pick-up on a CDI-carburettor bike) |
| Hall switch |
[ Hall effect sensor ]
Found on fuel injection bikes with latest CAN-BUS type ECU systems (e.g.
BMW). The Hall switch is often used as an ignition trigger and/or crankshaft
sensor reporting a digital signal to the engine’s ECU to determine
ignition timing |
| MAP sensor |
[ Air map sensor / Manifold Absolute Pressure sensor ]
Provides manifold pressure information to the ECU in order to determine
the correct fuel flow |
| Lambda sensor |
[ O2 / oxygen sensor ]
Determines whether the air fuel ratio exiting the combustion chamber is
rich (unburnt fuel vapour) or lean (excess oxygen) |
| STV sensor |
Secondary Throttle Valve sensor. On bikes with dual butterfly throttle
bodies (e.g. Suzuki GSXR750 K series 2001+) |
| Coolant temperature sensor |
Reports coolant temperature to ECU |
| Tilt sensor |
[ Bank sensor / lean angle sensor ]
Cuts fuel injection if bike is horizontal (i.e. as a safety feature in the
avent of an accident) |
| HT coil (s) |
[ ignition coil (s) / High Tension coils ]
Transforms the 12 volts from the battery to a higher voltage necessary for
the spark plugs to create a spark. Although commonly termed ‘ignition
coil’ there are other coils involved in the ignition system (e.g.
stator coils, pick-up coils), so it is best to use the term HT coil |
| Knock sensor |
Detects detonation inside the combustion chamber outside the normal combustion
cycle. If detonation occurs the ECU usually retards the ignition timing
to prevent the collision of different combustion fronts which could potentially
damage the engine |
| stick coils |
[ coil-on-plug / direct ignition coils ]
When the HT coils are incorporated into the spark plug caps rather than
being remotely positioned |
| generator |
[ alternator ]
Converts mechanical energy (i.e. from the engine’s crankshaft) into
alternating electrical current by utilising a rotating magnetic field. Generators
have two main components; the flywheel (rotor) which contains magnets, and
the stator which contains copper wire (windings). The flywheel rotates around
the stator to produce electrical energy. |
| stator |
[ stator plate / generator windings / alternator windings ]
Main component of the bike’s generator comprising copper wire wound
around a support frame. The stator remains stationary whilst the flywheel
rotates around it |
| flywheel |
[ rotor / generator rotor / alternator rotor ]
Main component of the bike’s generator containing magnets. The flywheel
rotates around the stator producing a magnetic field which generates alternating
electrical current (e.g. Kawasaki GPZ500 S EX500 A D) |
| pick-up coils |
[ pulser coil / / pulsar coil / signal generator ]
Detects the crankshaft speed from the generator flywheel or a separate timing
rotor and sends an electrical signal to the bike’s CDI unit (which
alters the ignition timing accordingly) |
|
|
| ELECTRICAL & IGNITION (continued) |
|
| points system |
Mechanical ignition timing system (e.g. early Honda CG125) |
| points |
[ contact breakers ]
Opens & breaks the electrical circuit that sends current to the HT coil(s)
in order to initiate a spark |
| points condensor |
Acts as a ‘mini-battery’ by storing electrical charge between
ignition cycles; component part of points ignition systems |
| points cam |
[ points camshaft ]
Small profiled camshaft which open & closes the points contacts on mechanical
ignition systems |
| points plate |
Metal plate mounting the points, points cam & condenser on mechanical
ignition systems |
| ATU |
[ Automatic Timing Unit / advance-retard unit ]
Found on mechanical (points) & early semi-electronic ignition systems
(e.g. Kawasaki GPz550 H KZ550H). The ATU changes the profile of the points
cam which alters the ignition timing. Usually operates by centrifugal force
driven by the rotational speed of the crankshaft |
| regulator |
[ voltage regulator ]
Electrical component designed to maintain a constant voltage level |
| rectifier |
Converts alternating current (AC) produced by the generator / alternator
to direct current (DC) used by the bike’s electrical systems &
stored in the battery |
| regulator-rectifier |
[ reg / rec ]
Combines regulator & rectifier functions into a single electrical unit
(e.g. Honda VFR750F / CBR600 F) |
| fuse box |
[ fuse holder ]
Contains the main fuses for the bike’s electrical systems |
| battery |
Usually 24 volt on modern bikes (e.g. Honda C90 Cub), but some early bikes
had 6 volt electrics (e.g. Honda C90 ZZ) |
| relay |
Electrical switch with a higher power output circuit than its input circuit.
Controls a high current circuit with a low current signal (e.g. starter
relay) |
| starter relay |
[ starter solenoid ]
Converts the low current signal sent by the ignition switch to a higher
current necessary to power the starter motor |
| diode |
Electrical component allowing current to pass in one direction only (blocking
it in the opposite direction) - often used to stop current passing from
one electrical circuit to another |
| resistor |
Electrical component designed to restrict the flow of electrical current.
The amount of resistance (measured in ohms) can be a fixed value or variable
(a potentiometer) |
| horn (s) |
-- |
|
|
| ENGINE |
|
| engine |
[ motor / lump ]
Can be supplied ‘complete’, stripped bare (basic engine), or
pretty much anywhere in between! Most breakers remove at least some ‘ancillary’
parts from an engine and sell them separately (which is fair enough - you
wouldn’t want to buy a complete engine if you only needed a starter
motor). So, if you ask for a ‘complete engine’ it may or may
not include the starter motor, outer engine covers, generator or clutch
etc. It is always worth double-checking exactly what you are getting for
the price quoted |
| complete engine & all running gear |
Generally accepted to mean the engine + everything required to make it
run - e.g. for a car project. Should include CDI / ECU, carbs / injectors,
wiring loom, generator, clutch etc, but can vary from model to model - some
fuel injected bikes may also need the clocks and/or ignition switch &
master key (for immobiliser) to make the engine run |
| bottom end |
[ short engine / bottom half ]
The engine without the barrels (unless part of the upper crank case) and
cylinder head. Includes the main crankcases, crankshaft & gearbox. You
need to check whether the generator, clutch & outer engine covers are
included or not |
| barrel / barrels |
[ cylinders ]
Part of the engine which the pistons(s) travel up & down inside. Some
modern bikes incorporate the barrels in the same casting as the upper crankcase.
V-four & V-twin bikes have two separate sets of barrels - If you don’t
need both, remember to specify which you need when ordering (i.e. front
/rear, RH / LH) |
| crankshaft |
[ crank ]
Steel shaft in the bottom of the engine which translates the linear motion
of the piston/s into rotation. The piston/s connect to the crankshaft by
connecting rods (con rods). Often sold as a set, i.e. crank & rods |
| crank casings |
Main structural part of the engine encasing the crankshaft and gearbox.
Crank cases can be split horizontally (i.e. top & bottom) or vertically
(RH & LH) and are machined from the same casting so should really be
sold as a matching pair. Not to be confused with the outer engine covers |
| pistons |
Often sold as a matching set with the barrel(s) i.e. barrel, piston &
rings. |
| pushrod (OHV engines) |
Situated between the camshaft (in the bottom end of the engine) and cylinder
head rocker (top of the engine). The camshaft profile moves the pushrod
upwards to engage the rocker which in turn opens a valve in the head |
| water jacket |
Situated above cylinder head on some two stroke bikes (e.g. Honda MTX125).
Seals the coolant flowing over the top of the barrel |
|
|
| ENGINE AUXILLARIES |
|
| starter motor |
[ electric starter / starting motor ]
Electric motor used to turn the engine over when starting the bike / scooter
(e.g. Cagiva River 500 Canyon 600 / Honda CBX750) |
| starter gears |
[ starter clutch ]
Mechanism (usually a series of gears) allowing the the starter motor to
turn the engine (e.g. Aprilia SL1000 Falco / Tuono 1000 / RSV Mille) |
| kickstart mechanism |
Mechanism (usually gears) allowing the kickstart lever/shaft to turn the
engine (e.g. Suzuki RM250 DR350 S / Kawasaki KX250 / Honda CR250 / Yamaha
WR250) |
| balance shaft |
An eccentric weighted shaft used to reduce engine vibration & other
stresses (e.g. Yamaha TDM850 TRX850) |
| cam chain |
[ camshaft chain ]
Chain providing drive to the camshaft(s) via the crankshaft |
| cam chain tensioner |
[ camshaft chain adjuster ]
Located on the rear of the cylinder head. Usually contains a spring &
ratchet mechanism which pushes a plunger to tension the cam chain |
| cam chain guide / guides |
Guides for the cam chain, often situated at the front & rear inside
the cylinder head |
| cam belt |
[ camshaft belt ]
Belt providing drive to the camshaft(s) via the crankshaft (e.g. Ducati) |
| cam belt guide |
|
| cam belt tensioner |
[ camshaft belt adjuster ] |
| cam gears |
[ cam drive gears ]
Linked set of gears providing drive from the crankshaft to the camshafts
(e.g. Honda VFR750) |
| oil pump (4 stroke engines) |
Mechanical pump circulating oil around the engine |
| oil pump (2 stroke engines) |
Mechanical pump delivering 2 stroke oil to the inlet manifold / cylinder
barrel |
|
|
| ENGINE COVERS |
|
| points cover |
Covers the contact breakers / points assembly on mechanical ignition bikes
(i.e. pre-electronic ignition) |
| clutch cover |
Large engine cover over the clutch assembly, usually (but not always)
on the RHS of the engine. On engines with a wet clutch the cover often has
a oil-slight glass / dipstick and aperture to replace / top up the engine
oil |
| front sprocket cover (chain drive) |
Cover over the front drive sprocket, usually (but not always) on the LHS
of the engine |
| transmission cover (chain drive) |
[ gearbox cover ]
Located behind the front sprocket (e.g. Kawasaki ZZ-R1100) |
| transmission cover (scooter/moped) |
Covers the variator & clutch assembly, usually on the LH side of the
engine |
| pick-up cover |
[ timing cover / pulsar cover / ignition cover ]
Small engine cover over the pick-up assembly (signal generator / pulser);
usually on the RHS of the engine |
| water pump cover |
[ water pump casing / impellor cover ] |
| cam cover |
[ rocker cover / cylinder head cover ] |
| sump |
[ sump pan / sump plate ]
Cover underneath the engine where oil pools when the bike is not in use.
Usually contains the oil drain plug |
|
|
| EXHAUST |
|
| complete exhaust system |
Full system including all component parts (downpipes, silencers, collector
etc) |
| downpipes |
[ headers / header pipes / exhaust manifold (4 stroke) / front pipe /s
(2 stroke) ] Front part of exhaust system that mounts to the cylinder head
(on 4 stroke engines) or cylinder barrel (on 2 stroke engines). Can be one
complete welded unit, or individual pipes |
| collector box |
Joins separate downpipes together & then attaches to the silencers
(usually twin silencer bikes) |
| link pipe |
[ intermediate pipe / connector pipe ]
Joins downpipes to silencer (usually single silencer bikes). As original
equipment it is often welded to silencer as one unit, but aftermarket performance
cans usually have separate link pipes |
| Silencer / silencers |
[ muffler / end can ]
Rear section of the exhaust containing the baffles / packing to reduce noise |
| race can |
Performance silencer, often without baffles or with removable baffles |
| exhaust downpipe valve |
[ EXUP valve (Yamaha) / HTEV / HVIX valve (Honda) / EXCV (Suzuki) ]
Flap / valve assembly situated in the exhaust manifold. Designed to increase
mid-range engine power by altering exhaust gas back-pressure. Progressively
opens (hi revs) or closes (low revs) depending on engine speed. Not to be
confused with an exhaust valve in the cylinder head of four stroke engines! |
| exhaust valve servo motor |
[ exhaust valve actuator / EXUP / HVIX / EXCV motor ]
Small electric motor which opens & closes the valve in the exhaust downpipes.
May also control a flap in the airbox to change air pressure / flow
|
| exhaust heat shield |
Usually on silencer - protects rider from exhaust heat |
| catalytic converter |
Unit containing precious metals to reduce exhaust gas emissions. Often
incorporated into the silencer assembly |
|
|
| FINAL DRIVE (BELT DRIVE) |
|
| drive belt |
[ final drive belt ]
A toothed belt which transmits drive from the front drive pulley to the
rear drive pully (e.g. Harley Davidson 883 Sportster 1200) |
| rear drive pully |
[ rear pulley ]
Connects to rear wheel & drive belt (e.g. Kawasaki GPz305 / EN500) |
| front drive pulley |
[ front pulley ]
Connects to gearbox output shaft & drive belt (e.g. BMW F650 CS Scarver) |
| FINAL DRIVE (CHAIN DRIVE) |
|
| chain & sprocket set |
[ chain & sprockets ]
Comprises the drive chain, front & rear sprockets. Ideally all should
be changed together so they wear at the same rate |
| rear sprocket carrier |
Holds rear drive sprocket & has lugs that slot into the rear wheel |
| cush drive rubbers |
Fits between the lugs on the sprocket carrier & the rear wheel. Provides
a cushion between the wheel & rear sprocket during acceleration &
engine braking |
