The mechanic likely consulted the shop manual for the servicing, and used the parts catalog to order parts.
What are a shop manual and parts catalog?
Now, let’s introduce the shop manual and parts catalog.
1.Info about the Shop Manual
What is a shop manual?
A shop manual is a service guide containing information for motorcycle mechanics.
What sort of information does the shop manual include?
The shop manual covers vehicle inspection/diagnosis, disassembly, parts inspection/replacement, and assembly procedures.
Let’s begin with brake pad replacement as an example.
Inspection / Diagnosis
Disassembly → Replacement
Assembly
It describes vehicle inspection/diagnosis, disassembly, parts inspection/replacement, and assembly procedures.
During assembly in particular, torque values like 40 N-m or 45 N-m show how tightly bolts should be tightened. “NEW” means that parts must be replaced with new ones after vehicle disassembly.
So much detail.
Even just tightening one bolt during assembly can be tricky...
Next, vehicle and component inspection methods are listed below for specific parts of the vehicle.
That’s a lot of inspections, isn’t it?
Furthermore, when the PGM-FI malfunction indicator lamp—a warning light that alerts the rider of a vehicle malfunction—turns on, we diagnose and repair the issue according to the shop manual using the Diagnostic Trouble Code (DTC) from the Motorcycle Communication System (MCS).
A shop manual really contains a wealth of information, doesn’t it!
2.Info about the Parts Catalog
What is a parts catalog?
A parts catalog is a reference guide that helps mechanics identify the form, part number, and the quantity of components to be replaced.
What sort of things does the parts catalog include?
All motorcycle parts are shown in exploded diagrams with their corresponding part numbers.
Example: “2” represents the Front Pad Set, part number 06455-MKR-D11, and two are used on the vehicle.
While consulting the shop manual, we identify the part numbers for replacement parts and order the parts using the parts catalog.
Furthermore, the parts catalog specifies the flat rate time for each part, which is used to calculate the labor cost for replacement.
(This information is not provided for certain regions or models.)
For example, for the replacement of the Front Pad Set, the catalog states:
Replacement of right or left side only: 0.1 hours
Replacement of both sides: 0.2 hours.
It's the seamless integration of the shop manual and parts catalog, right?
Just knowing these systems work behind the scenes makes maintenance reassuring!
The other day, I had my motorcycle serviced at the dealer.
When I looked in, the mechanic was working while referring to something.
He appeared to be verifying parts using an exploded diagram.