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 . . . . . . POST SERVICE REPORT – RECOMMENED/UPCOMING MAINTENCE