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Assessment Criteria for IMI QUALIFICATION IMI Level 3 Certificate in Cycle Maintenance I.D No: 601/4577/8 To be used in conjunction with Candidate Assessment Summary, Practical and Written Assignments For assessor use only: Assessor Verifier Guidance 01-10-2014 / Version 1

CENTRE INFORMATION Please be aware that any legislation referred to in this qualification may be subject to amendment/s during the life of this qualification. Therefore IMI Approved Centres must ensure they are aware of and comply with any amendments, e.g. to health and safety legislation and employment practices. Please be aware that vehicle technologies referred to in this qualification reflect current practice, but may be subject to amendment/s, updates and replacements during the life of this qualification. Therefore IMI Approved Centres must ensure they are aware of the latest developments and emerging technologies to ensure the currency of this qualification. Please note: the relevance of the information contained in the unit content will vary depending upon the vehicle types being worked upon. The unit content is for guidance only and is not meant to be prescriptive. 2015 IMI All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of IMI Requests should be made in writing and addressed to: Institute of the Motor Industry (IMI) Fanshaws, Brickendon, Hertford SG13 8PQ

CONTACT SHEET Learner Name: Learner Registration No: Learner Address: Learner Tel No: Learner Email: Employer Contact: Employer Name & Address: Employer Tel No: Please complete as appropriate: Witness Name: Witness Job Title: Witness Signature: Witness Name: Witness Job Title: Witness Signature: Witness Name: Witness Job Title: Witness Signature: Witness Name: Witness Job Title: Witness Signature: Assessor Name: Assessor Signature: Assessor Name: Assessor Signature: Assessor Name: Assessor Signature: Internal Verifier Name: Internal Verifier Signature: Internal Verifier Name: Internal Verifier Signature: 3

IMI Level 3 Certificate in Cycle Maintenance ID NO: 601/4577/8 In order to achieve the qualification, learners must achieve a minimum of 26 credits Group A: A minimum of 24 credits must be achieved Group B: A minimum of 2 credits must be achieved Note: Assessments and Assignments The assessments/assignments for this qualification combine various assessment/assignment styles/methodologies in order to suit the levels of units contained within it. The table below clarifies what IMI assessments/assignments are available for each unit, and whether these assessments/assignments are mandatory (M) or optional (O) for the selected unit. The key below details the style of assessment/s: W = Written Assignments P = Practical Assessments Group A Mandatory Units Unit Ref: Unit Title and ID Number GLH BC20 BC21 Carry out Routine Maintenance on a Cycle (L/506/6697) Identifying and Agreeing Customer Requirements (R/506/6698) Unit Level Credit Value Assessments W P 41 3 6 M M 9 3 2 M M BC22 Cycle Wheel Building (Y/506/6699) 41 3 5 M M BC23 BC24 BC25 BC26 BC27 Maintain and Repair Cycle Hydraulic Disc Brake Systems (F/506/6700) Maintain and Repair Cycle Suspension Systems (J/506/6701) Maintain and Repair Cycle Complex Wheels (L/506/6702) Identify and Replace Cycle Advanced Headset and Bearings (R/506/6703) Refurbish Cycle Bottom Brackets and Cranks (Y/506/6704) 17 3 3 M M 17 3 3 M M 9 3 2 M M 5 3 2 M M 5 3 1 M M Group B Optional Units Unit Ref: Unit Title and ID Number BC28 Maintain and Repair Cycle Complex Internal Hub Systems (D/506/6705) BC29 Principles of Cycle Frame Alignment and Cycle Frame Geometrics (H/506/6706) BC30 Diagnose and Rectify Cycle Electronic Gear Change System Faults (K/506/6707) BC31 Electrically Propelled Cycle Awareness (M/506/6708) GLH Unit Level Credit Value Assessments W P 9 3 2 M M 5 3 2 M 3 3 1 M M 5 3 1 M 4

UNIT REF: BC20 UNIT TITLE: CARRY OUT ROUTINE MAINTENANCE ON A CYCLE Level: 3 Credit Value: 6 GLH: 41 Rationale: The aim of this unit is to provide the learner with the skills and knowledge required to carry out routine maintenance on a cycle. This includes stripping the cycle to the frame, checking the alignment and rebuilding as a new cycle. LEARNING OUTCOMES The Learner will: 1. be able to work efficiently and safely carrying out routine maintenance on a cycle ASSESSMENT CRITERIA The Learner can: 1.1. use appropriate Personal Protective Equipment and safety methods when carrying out routine maintenance on a cycle 1.2. demonstrate Health and Safety workplace procedures when carrying out routine maintenance on a cycle 1.3. demonstrate and describe workplace and legislative procedures for handling, disposal and recycling of used and waste materials 1.4. work minimising the risk of damage to the cycle, its systems, the environment, other people and their property 2. be able to use relevant sources of information when carrying out routine maintenance on a cycle 1.5. explain the importance of working to agreed timescales and keeping others informed of progress 2.1. ensure that records for carrying out routine maintenance on cycles are accurate 2.2. state the importance of following correct technical data when carrying out routine maintenance on cycles 3. know how to systematically carry out routine maintenance on cycles 3.1. state the different stages of a systematic cycle strip to the frame 3.2. state the process for checking the alignment of a cycle frame and the tolerances to be adhered to 3.3. explain the checks to be carried out to the wheels 3.4. state the different stages of a systematic cycle rebuild following a frame alignment check to include: a. degreasing b. cleaning c. lubricating d. adjustment 4. be able to select and use the appropriate tools and equipment to carry out routine maintenance on cycles 4.1. demonstrate how to prepare and use all the equipment required to carry out a systematic routine maintenance activity on a cycle 5

5. be able to carry out a systematic cycle strip to the frame 5.1. demonstrate the correct procedure for stripping a cycle to the frame 5.2. store all the removed component parts safely following workplace procedures 5.3. assess the serviceability of all the removed component parts 5.4. identify and report damaged or faulty cycle component parts to the relevant person(s) 6. be able to carry out a cycle frame alignment check 6.1. clean and assess the overall cosmetic condition of the cycle frame 6.2. identify any structural damage to the cycle frame and recommend any further action 6.3. perform a cycle frame alignment check 6.4. record the results from the cycle frame alignment check 7. be able to carry out a systematic cycle rebuild following a frame alignment check 7.1. prepare all the component parts of the cycle for refitting to include: a. degreasing b. cleaning c. lubricating 7.2. assess the tension and trueness of the wheels and make any required adjustments 7.3. demonstrate the correct procedure for refitting the component parts of the cycle 7.4. carry out adjustments to the refitted component parts of the cycle 8. know how to carry out a quality check on a cycle and its component parts following routine maintenance 8.1. state the quality check process following the routine maintenance of a cycle 8.2. explain how to report any faults identified during the quality check 8.3. describe the process for rectifying any faults highlighted during the quality check 9. be able to carry out a quality check on the cycle and its component parts following the routine maintenance activity 9.1. assess the condition of the cycle and its component parts following the routine maintenance activity to include: a. cleanliness b. security of all component parts c. adjustment of all component parts d. lubrication of all component parts ensure the cycle is returned to any specific customer specification 9.2. accurately complete all documentation and pass it to the relevant person(s) 6

Content: Sources of information a. Manufacturer s instructions from distributors and websites b. Specific brand maintenance requirements c. Servicing criteria d. M-Check or check list e. EN14764 f. The Pedal Bicycles (Safety) Regulations 2010 g. Test riding h. Safety equipment Component parts a. Front and rear derailleur b. Derailleur cables c. Chain d. Pedals e. Crank f. Jockey wheels g. Gear shift mechanisms h. Brake discs i. Brake pads j. Brake operation levers k. Brake cables l. Brake lines m. Handlebars n. Headsets o. Front forks including suspension components p. Rear suspension components q. Wheels r. Saddle and stem s. Mud guards t. Side stands u. Accessories including lighting, luggage, speedometer, satellite navigation Adjustments a. Rear derailleur H&L b. Front derailleur H&L c. Gear indexing d. Front brake lever travel to BS6102 e. Rear brake lever travel to BS6102 f. Brake adjustment screws g. Forks in line h. Handlebars & headsets i. Saddle height j. Wheel tension k. Suspension travel and rebound Tools and equipment a. Hand tools b. Electrical tools c. Measuring equipment d. Bench mounted equipment e. Power tools f. Cleaning and degreasing equipment Level 3 Certificate in Cycle Maintenance Assessment Criteria Lubrication a. Rear derailleur b. Front derailleur c. Chain d. Jockey wheel(s) e. Crank f. Pedal bearings g. Joints and pivots 7

Evidence Requirements You must: 1. produce evidence to show you meet all of the Learning Outcomes. 2. produce performance evidence resulting from work you have carried out in your training workshop as managed and organised by an approved centre. 3. be observed by an assessor. 1. You must be observed by your assessor successfully and systematically carrying out all of the activities listed below on at least 2 occasions. Evidence Ref: a. removing all component parts from a cycle frame b. cleaning and inspecting a cycle frame without any component parts c. checking and reporting on cycle frame alignment d. degreasing, cleaning and lubricating cycle component parts e. refitting all component parts to a cycle frame f. checking and adjusting component parts on a cycle 2. You must be observed by your assessor successfully carrying out a quality check covering all of the areas listed below. a. cleanliness Evidence Ref: b. security of component parts c. adjustment of component parts d. lubrication of component parts e. customer specification Assessor Signature: Pin No: Date: 8

UNIT REF: BC21 UNIT TITLE: IDENTIFYING AND AGREEING CUSTOMER REQUIREMENTS Level: 3 Credit Value: 2 GLH: 9 Rationale: The aim of this unit is to provide the learner with the skills and knowledge required to gain information from customers on their perceived requirements; give advice and information, agree a course of action and a contract for the agreed work. It also covers completing all the necessary records and instructions. LEARNING OUTCOMES The Learner will: 1. understand legislative and organisational requirements and procedures ASSESSMENT CRITERIA The Learner can: 1.1 describe the fundamental legal requirements of current consumer legislation and the consequences of their own actions in respect of this legislation 1.2 describe the content and limitations of company and product warranties for the cycles dealt with by their company 1.3 explain the limits of their own authority for accepting cycles 1.4 explain the importance of keeping customers informed of progress 1.5 describe their workplace requirements for the completion of records 2. understand how to communicate and care for customers 1.6 explain how to complete and process all the necessary documentation 2.1 explain how to communicate effectively with customers 2.2 describe how to adapt your language when explaining technical matters to non-technical customers 2.3 explain how to use effective questioning techniques 2.4 describe how to care for customers and achieve customer satisfaction 3. be able to obtain relevant information from the customer 3.1 obtain and interpret sufficient, relevant information, from the customer to make an assessment of their requirement 3.2 clarify customer and cycle needs by referring to cycle data and operating procedures 9

4. be able to provide relevant information to the customer 4.1 provide customers with accurate, current and relevant advice and information, in a form that the customer will understand 4.2 demonstrate techniques which encourage customers to ask questions and seek clarification during conversation 5. understand company products and services 5.1 describe the range of options available to resolve cycle problems 5.2 describe the range and type of services offered by their company 5.3 explain the effect of resource availability upon the receipt of customer cycles and the completion work 5.4 explain how to access costing and work completion time information 6. be able to agree work undertaken with the customer 6.1 summarise and record work agreed with the customer, before accepting the cycle 6.2 implement confirmation of the agreement by ensuring customer understanding 7. be able to ensure recording systems are implemented correctly 7.1 use recording systems which are accurate and complete, in the required format and signed by the customer where necessary 7.2 perform the next stage in the process by passing on completed records to the correct person promptly 7.3 demonstrate correct procedures for customer approval where the contracted agreement is likely to be exceeded 10

Content: Organisational requirements a. Explain the organisation s terms and conditions applicable to the acceptance of customer cycles. b. Explain the content and limitations of cycle and component part warranties for the cycles dealt with by your organisation. c. Detail what, if any, limits there are to the authority for accepting cycles. d. Detail why it is important to keep customers advised of progress and how this is achieved within the organisation. e. Detail the organisation s procedures for the completion and processing of documentation and records, including payment methods and obtaining customer signatures as applicable. Customer requirements a. Frame selection b. Frame geometry c. Wheel selection d. Accessories e. Cycle set-up f. Maintenance g. Fitting h. Servicing Principles of customer communication and care a. First Impressions. b. Listening skills 80:20 ratio. c. Eye contact and smiling. d. Showing interest and concern. e. Questioning techniques and customer qualification. f. Giving clear non-technical explanations. g. Confirming understanding (statement/question technique, reflective summary). h. Written communication purpose, content, presentation and style. i. Providing a high quality service fulfilling (ideally exceeding) customer expectations within agreed time frames. j. Obtaining customer feedback and corrective actions when dissatisfaction is expressed. k. Dealing with complaints. Company products and services a. Service standards i. national ii. manufacturer iii. organisational b. The range and type of services offered by the organisation i. diagnostic ii. servicing/maintenance iii. repair iv. warranty v. fitment of accessories/enhancements vi. internal c. The courses of action available to resolve customer problems i. the extent and nature of the work to be undertaken ii. the terms and conditions of acceptance iii. the cost iv. the timescale v. required payment methods d. Effect of resource availability upon the receipt of customer cycles and the completion of work i. levels and availability of equipment ii. levels and availability of technicians iii. workshop loading systems 11

Content Cont. e. How to access costing and work completion time information i. manuals ii. computer based Cycle Information Systems, Servicing and Repair Requirements a. Accessing technical data including diagnostics b. Servicing to manufacturer requirements/standards c. Repair/operating procedures d. Quality controls interim and final e. Requirements for cleanliness of cycle on return to customer f. Handover procedures Consumer legislation to include: a. Consumer protection b. Sale of goods c. Data protection d. Product liability e. Health and safety f. Discrimination Evidence Requirements You must: 1. produce evidence to show you meet all of the Learning Outcomes. 2. produce performance evidence resulting from work you have carried out in your training workshop as managed and organised by an approved centre. 3. be observed by an assessor. 1. You must be observed by an assessor dealing with 3 different customers. Evidence Ref: Evidence from real activity or role-play is acceptable for this unit Assessor Signature: Pin No: Date: 12

UNIT REF: BC22 UNIT TITLE: CYCLE WHEEL BUILDING Level: 3 Credit Value: 5 GLH: 41 Rationale: The aim of this unit is to provide the learner with the skills and knowledge required to build a cycle wheel so that the cycle is left in a safe and roadworthy condition. LEARNING OUTCOMES The Learner will: 1. be able to work efficiently and safely when building a cycle wheel 2. know how to use relevant sources of information to build a cycle wheel. ASSESSMENT CRITERIA The Learner can: 1.1. use the appropriate Personal Protective Equipment and safety methods when lacing, tensioning and truing a cycle wheel 1.2. demonstrate Health and Safety workplace procedures relating to wheel building 1.3. demonstrate and describe workplace and legislative procedures for handling, disposing and recycling of used and waste material 1.4. work in a way which minimises the risk of damage to the cycle, its systems, the environment, other people and their property 1.5. explain the importance of working to agreed timescales and keeping others informed of progress 2.1. ensure that records for wheel building are accurate 2.2. state the importance of following correct technical data for wheel building 2.3. collect data required to calculate correct spoke lengths for a wheel 3. know how cycle wheels components function 3.1. name the main unit components and features of wheels 4. select and use the appropriate tools and equipment to build a cycle wheel 5. carry out the lacing, truing and tensioning of a dished wheel 3.2. identify all of the following: a. common spoke lacing patterns b. leading and trailing spokes c. inbound and outbound spokes 4.1. demonstrate how to prepare and use the equipment required to measure, build and test a cycle wheel 5.1. state how manufacturer s data can be used to select wheel components which are compatible with each other and suitable for the intended use of the wheel 5.2. perform calculations (traditional or web-based methods) to determine correct spoke lengths for a dished wheel 5.3. demonstrate lacing, tensioning and truing of a dished wheel with a three-cross pattern, which has a minimum diameter of 26 inch (ERTO 559) 5.4. demonstrate stress relieving spokes 5.5. demonstrate techniques which minimise spoke wind-up 5.6. compare against recommended spoke tensions 5.7. recognise and report cosmetic damage to wheel components to the relevant person 13

Content: a. Obtaining manufacturer s instructions from distributors and websites b. Specific brand maintenance requirements c. Rim types d. Spoke types e. Hub types f. Lacing patterns g. Optimum spoke tensions h. Calculation spoke lengths i. Rim preparation j. Spoke preparation k. De-stressing wheels l. Safety equipment m. Waste disposal Evidence Requirements You must: 1. produce evidence to show you meet all of the Learning Outcomes. 2. produce performance evidence resulting from work you have carried out in your training workshop as managed and organised by an approved centre. 3. be observed by an assessor. 1. You must be observed by your assessor successfully carrying out all of the activities listed below on at least 2 occasions. Evidence Ref: a. lace and tension a dished wheel with a three-cross pattern (min 26 ) b. true a dished wheel with a three-cross pattern (min 26 ) c. stress relieve spokes on a dished wheel with a three-cross pattern (min 26 ) Assessor Signature: Pin No: Date: 14

UNIT REF: BC23 UNIT TITLE: MAINTAIN AND REPAIR CYCLE HYDRAULIC BRAKE SYSTEMS Level: 3 Credit Value: 3 GLH: 17 Rationale: The aim of this unit is to provide the learner with the skills and knowledge required to maintain and repair cycle hydraulic brake systems and faults. This unit also includes carrying out a quality check on the completed work before returning the cycle to the customer. LEARNING OUTCOMES The Learner will: 1. be able to work efficiently and safely maintaining and repairing cycle hydraulic brake systems ASSESSMENT CRITERIA The Learner can: 1.1 use appropriate Personal Protective Equipment and safety methods when maintaining and repairing cycle hydraulic brake systems 1.2 demonstrate Health and Safety workplace procedures when maintaining and repairing cycle hydraulic brake systems 1.3 demonstrate and describe workplace and legislative procedures for handling, disposal and recycling of used and waste materials 1.4 work minimising the risk of damage to the cycle, its systems, the environment, other people and their property 2. be able to use relevant sources of information when maintaining and repairing cycle hydraulic brake systems 1.5 explain the importance of working to agreed timescales and keeping others informed of progress 2.1 ensure that records for maintaining and repairing cycle hydraulic brake systems are accurate 2.2 state the importance of following correct technical data when maintaining and repairing cycle hydraulic brake systems 2.3 find and interpret manufacturer s instructions 3. know how a cycle hydraulic brake system operates 3.1 state the components relating to a cycle hydraulic brake system 3.2 explain the purpose and operation of each component of a cycle hydraulic brake system 3.3 identify the advantages and disadvantages of various cycle hydraulic brake designs 3.4 state the faults associated with cycle hydraulic brake systems to include: a. fluid leaks b. excessive travel c. noises d. poor braking efficiency 3.5 identify and explain the relevant BS EN standards that refer to cycle hydraulic brake system safety requirements and test methods 3.6 explain the affect of air in a cycle hydraulic brake system 15

4. be able to select and use the appropriate tools and equipment to maintain and repair cycle hydraulic brake systems 5. be able to carry out maintenance and repairs to cycle hydraulic brake systems 4.1 demonstrate how to prepare and use all the equipment required to maintain and repair cycle hydraulic brake systems 5.1 demonstrate the correct procedure for inspecting a cycle hydraulic brake system 5.2 remove and assess the serviceability of cycle hydraulic brake system components 5.3 refit or replace cycle hydraulic brake system components following workshop/manufacturer s procedures 5.4 adjust cycle hydraulic brake system components following manufacture s specification 5.5 bleed a cycle hydraulic brake system following workshop/manufacturer s guidelines 5.6 identify and rectify faults presented on cycle hydraulic brake systems 5.7 identify and report damaged or faulty cycle hydraulic brake system component parts to the relevant person(s) 6. be able to carry out a cycle hydraulic brake system function test and record their findings 6.1 carry out a cycle hydraulic brake system function test prior to commencing any rectification work and record their results 6.2 carry out a cycle hydraulic brake system function test following rectification work and record their results 6.3 pass on the results of the pre and post rectification function test to the relevant person(s) 7. know how to carry out a quality check on a cycle hydraulic brake system following maintenance and repair activities 7.1 state the quality check process following the maintenance and repair activity 7.2 explain how to report any faults identified during the quality check 7.3 describe the process for rectifying any faults highlighted during the quality check 8. be able to carry out a quality check on the cycle hydraulic brake system following the maintenance or repair activity 8.1 assess the condition of the cycle hydraulic brake system following the maintenance or repair activity to include: a. cleanliness b. security of all component parts c. adjustment of brake operating lever travel d. fluid leaks e. function test 8.2 ensure the cycle is returned to the customer in a roadworthy and clean condition 8.3 accurately complete all documentation and pass it to the relevant person(s) 16

Content: Sources of information a. Manufacturer s instructions from distributors and websites b. Specific brand maintenance requirements c. Servicing criteria d. M-Check or check list e. EN14764 f. The Pedal Bicycles (Safety) Regulations 2010 g. Test riding h. Safety equipment i. BS EN Standards i. BS EN 14764 City and trekking bicycles safety requirements and test methods ii. BS EN 14765 Bicycles for young children safety requirements and test methods iii. BS EN 14766 Mountain bicycles safety requirements and test methods iv. BS EN 14781 Racing bicycles safety requirements and test methods v. BS EN 15194 Electrically power assisted cycles Cycle hydraulic brake system components a. Brake operating lever b. Hydraulic brake fluid lines c. Hydraulic oil reservoir d. Hydraulic brake calipers e. Brake pads f. Brake discs g. Brake cables Adjustments a. Brake operating lever screw b. Brake cable c. Cable brackets d. Fluid level Tools and equipment a. Hand tools b. Electrical tools c. Measuring equipment d. Bench mounted equipment e. Power tools f. Brake bleeding equipment g. Cleaning and degreasing equipment 17

Evidence Requirements You must: 1. produce evidence to show you meet all of the Learning Outcomes. 2. produce performance evidence resulting from work you have carried out in your training workshop as managed and organised by an approved centre. 3. be observed by an assessor. 1. You must be observed by your assessor successfully carrying out all of the activities listed below on at least 2 occasions. a. brake function test pre rectification b. brake function test post rectification c. replacement of brake pads d. clean, inspect and measure brake discs e. inspect and adjust brake operating cable f. inspect hydraulic fluid lines for damage and leaks g. bleed cycle hydraulic brake systems following manufacturer s guidelines 2. You must be observed by your assessor successfully carrying out a quality check covering all of the areas listed below. a. cleanliness b. security of component parts c. adjustment of brake operating lever travel d. fluid leaks e. function test Evidence Ref: Evidence Ref: Assessor Signature: Pin No: Date: 18

UNIT REF: BC24 UNIT TITLE: MAINTAIN AND REPAIR CYCLE SUSPENSION SYSTEMS Level: 3 Credit Value: 3 GLH: 17 Rationale: The aim of this unit is to provide the learner with the skills and knowledge required to maintain and repair cycle suspension systems and faults. This unit also includes carrying out a quality check on the completed work before returning the cycle to the customer. LEARNING OUTCOMES The Learner will: 1. be able to work efficiently and safely maintaining and repairing cycle suspension systems ASSESSMENT CRITERIA The Learner can: 1.1 use appropriate Personal Protective Equipment and safety methods when maintaining and repairing cycle suspension systems 1.2 demonstrate Health and Safety workplace procedures when maintaining and repairing cycle suspension systems 1.3 demonstrate and describe workplace and legislative procedures for handling, disposal and recycling of used and waste materials 1.4 work minimising the risk of damage to the cycle, its systems, the environment, other people and their property 2. be able to use relevant sources of information when maintaining and repairing cycle suspension systems 1.5 explain the importance of working to agreed timescales and keeping others informed of progress 2.1 ensure that records for maintaining and repairing cycle suspension systems are accurate 2.2 state the importance of following correct technical data when maintaining and repairing cycle suspension systems 2.3 find and interpret manufacturer s instructions 2.4 explain the difference between a hard tail and a full suspension cycle 3. know how a cycle front suspension system operates 3.1 state the component parts of a typical telescoping front fork assembly 3.2 explain the purpose and operation of each component of a typical cycle telescoping front fork assembly 3.3 identify the advantages and disadvantages of the following front suspension fork systems: a. elastomer spring and damping b. steel coil spring/elastomer damping c. steel coil spring/oil damping d. air suspension/oil damping 19

3.4 explain the meaning of the following terminology in relation to cycle suspension: a. suspension b. damping c. bottoming out d. travel e. preload f. stiction g. rebound rate 3.5 state the purpose of a lock out adjuster 3.6 state the common reasons for faults associated with cycle front suspension systems to include: a. poor response b. progressive suspension sagging c. progressive suspension stiffening d. bottoming out 4. know how a cycle rear suspension system operates 4.1 state the main differences between a suspension seatpost, a single pivot swing arm and a multiple linkage rear cycle suspension system 4.2 identify the main advantages and disadvantages of a suspension seatpost, a single pivot swing arm and a multiple linkage rear cycle suspension system 4.3 explain the main purpose of an inertia valve 4.4 identify the main components relating to a cycle rear suspension system 5. be able to select and use the appropriate tools and equipment to maintain and repair cycle suspension systems 6. be able to carry out maintenance and repairs to cycle suspension systems 5.1 demonstrate how to prepare and use all the equipment required to maintain and repair cycle suspension systems 6.1 demonstrate the correct procedure for inspecting a cycle suspension system 6.2 remove and assess the serviceability of cycle suspension system components 6.3 refit or replace cycle suspension system components following workshop/manufacturer s procedures 6.4 adjust cycle suspension system components and settings following manufacture s specification 6.5 identify and rectify faults presented on cycle suspension systems 6.6 identify and report damaged or faulty cycle suspension system component parts to the relevant person(s) 20

7. be able to carry out a cycle suspension system function test and record their findings 7.1 carry out a cycle suspension system function test prior to commencing any rectification work and record their results 7.2 carry out a cycle suspension system function test following rectification work and record their results 7.3 pass on the results of the pre and post rectification function test to the relevant person(s) 8. know how to carry out a quality check on a cycle suspension system following maintenance and repair activities 8.1 state the quality check process following the maintenance and repair activity 8.2 explain how to report any faults identified during the quality check 8.3 describe the process for rectifying any faults highlighted during the quality check 9. be able to carry out a quality check on the cycle suspension system following the maintenance or repair activity 9.1 assess the condition of the cycle suspension system following the maintenance or repair activity to include: a. cleanliness b. security of all component parts c. adjustment of travel and preload d. function test 9.2 ensure the cycle is returned to the customer in a roadworthy and clean condition 9.3 accurately complete all documentation and pass it to the relevant person(s) 21

Evidence Requirements You must: 1. produce evidence to show you meet all of the Learning Outcomes. 2. produce performance evidence resulting from work you have carried out in your training workshop as managed and organised by an approved centre. 3. be observed by an assessor. 1. You must be observed by your assessor successfully carrying out all of the activities listed below on at least 2 occasions. Evidence Ref: a. suspension function test pre rectification b. suspension function test post rectification c. replacement of front suspension component d. replacement of rear suspension component e. check and adjust travel and preload on front suspension f. lubricate rear pivots and bushes g. strip and rebuild front suspension fork system and oil/lubricate 2. You must be observed by your assessor successfully carrying out a quality check covering all of the areas listed below. Evidence Ref: a. cleanliness b. security of component parts c. adjustment travel and preload d. function test Assessor Signature: Pin No: Date: 23

UNIT REF: BC25 UNIT TITLE: MAINTAIN AND REPAIR CYCLE COMPLEX WHEELS Level: 3 Credit Value: 2 GLH: 9 Rationale: The aim of this unit is to provide the learner with the skills and knowledge required to maintain and repair cycle complex wheels. This unit also includes carrying out a quality check on the completed work before returning the cycle to the customer. LEARNING OUTCOMES The Learner will: 1. be able to work efficiently and safely maintaining and repairing cycle complex wheels ASSESSMENT CRITERIA The Learner can: 1.1 use appropriate Personal Protective Equipment and safety methods when maintaining and repairing cycle complex wheels 1.2 demonstrate Health and Safety workplace procedures when maintaining and repairing cycle complex wheels 1.3 demonstrate and describe workplace and legislative procedures for handling, disposal and recycling of used and waste materials 1.4 work minimising the risk of damage to the cycle, its systems, the environment, other people and their property 2. be able to use relevant sources of information when maintaining and repairing cycle complex wheels 1.5 explain the importance of working to agreed timescales and keeping others informed of progress 2.1 ensure that records for maintaining and repairing cycle complex wheels are accurate 2.2 state the importance of following correct technical data when maintaining and repairing cycle complex wheels 2.3 find and interpret manufacturer s instructions 3. know and understand a cycle complex wheel system 3.1 describe what is meant by a complex wheel system 3.2 state the component parts which make up a complex cycle wheel 3.3 explain the purpose and operation of each complex cycle wheel component part 3.4 identify and describe 5 different complex hubs and their design 3.5 state the common use and design of the following rim types: a. clincher b. tubular or sew-ups c. tubeless 3.6 identify and explain the relevant BS EN standards that refer to the maintenance and repair of cycle complex wheel systems 24

4. be able to select and use the appropriate tools and equipment to maintain and repair cycle complex wheels 5. be able to carry out maintenance and repairs to cycle complex wheel systems 4.1 demonstrate how to prepare and use all the equipment required to maintain and repair cycle complex wheels 5.1 demonstrate the correct procedure for inspecting a cycle complex wheel 5.2 remove and assess the serviceability of a cycle complex wheel 5.3 remove, replace and lubricate bearings in a complex cycle wheel hub 5.4 adjust complex cycle wheel bearings in accordance with manufacturer s specification 5.5 recognise and report cosmetic damage to complex cycle wheels in the format required and pass to the relevant person(s) 5.6 refit the complex cycle wheel ensuring correct adjustment and security 5.7 identify and rectify faults presented on cycle complex wheel systems 5.8 identify and report damaged or faulty cycle complex wheel system component parts to the relevant person(s) 6. know how to carry out a quality check on a cycle complex wheel system following maintenance and repair activities 6.1 state the quality check process following the maintenance and repair activity 6.2 explain how to report any faults identified during the quality check 6.3 describe the process for rectifying any faults highlighted during the quality check 7. be able to carry out a quality check on the cycle complex wheel system following the maintenance or repair activity 7.1 assess the condition of the cycle complex wheel system following the maintenance or repair activity to include: a. cleanliness b. security of all component parts c. adjustment of bearings d. tension of spokes e. trueness of the wheel f. function test 7.2 ensure the cycle is returned to the customer in a roadworthy and clean condition 7.3 accurately complete all documentation and pass it to the relevant person(s) 25

Content: Sources of information a. Manufacturer s instructions from distributors and websites b. Specific brand maintenance requirements c. Servicing criteria d. M-Check or check list e. EN14764 f. The Pedal Bicycles (Safety) Regulations 2010 g. Test riding h. Safety equipment i. BS EN Standards i. BS EN 14764 City and trekking bicycles safety requirements and test methods ii. BS EN 14765 Bicycles for young children safety requirements and test methods iii. BS EN 14766 Mountain bicycles safety requirements and test methods iv. BS EN 14781 Racing bicycles safety requirements and test methods v. BS EN 15194 Electrically power assisted cycles Complex wheel system component parts a. Hub shell b. Axle c. Bearings d. Rim e. Hub brake attachment f. Spokes/blades Complex hubs a. Hope b. Mavic c. Campg d. Easton e. Chris King Rear hub designs a. Freehub b. Freewheel c. Track sprocket d. Flip-flop-hub e. Internal geared hub Adjustments a. Bearings b. Wheel torque settings c. Tyre pressures Tools and equipment a. Hand tools b. Electrical tools c. Measuring equipment d. Bench mounted equipment e. Power tools f. Cleaning and degreasing equipment g. Pneumatic pressurising equipment 26

Evidence Requirements You must: 1. produce evidence to show you meet all of the Learning Outcomes. 2. produce performance evidence resulting from work you have carried out in your training workshop as managed and organised by an approved centre. 3. be observed by an assessor. 3. You must be observed by your assessor successfully carrying out all of the activities listed below on at least 2 occasions. Evidence Ref: a. inspect a complex wheel using prescribed procedure b. remove and assess serviceability of a complex wheel c. remove, replace and lubricate complex wheel bearings d. correctly adjust bearings in a complex wheel to manufacturer s specification e. refit complex cycle wheel and carry out all adjustments to manufacturer s specification 4. You must be observed by your assessor successfully carrying out a quality check covering all of the areas listed below. Evidence Ref: a. cleanliness b. security of component parts c. adjustment of bearings d. tension of spokes e. trueness of wheel f. function test Assessor Signature: Pin No: Date: 27

UNIT REF: BC26 UNIT TITLE: IDENTIFY AND REPLACE CYCLE ADVANCED HEADSETS AND BEARINGS Level: 3 Credit Value: 2 GLH: 5 Rationale: The aim of this unit is to provide the learner with the skills and knowledge required to identify and replace cycle advanced headsets and bearings. This unit also includes carrying out a quality check on the completed work before returning the cycle to the customer. Note: It is recommended that BC19 Service Cycle Headset Assemblies is completed prior to this unit. LEARNING OUTCOMES The Learner will: 1. be able to work efficiently and safely removing and replacing cycle advanced headsets and bearings ASSESSMENT CRITERIA The Learner can: 1.1 use appropriate Personal Protective Equipment and safety methods when removing and replacing cycle advanced headsets and bearings 1.2 demonstrate Health and Safety workplace procedures when removing and replacing cycle advanced headsets and bearings 1.3 demonstrate and describe workplace and legislative procedures for handling, disposal and recycling of used and waste materials 1.4 work minimising the risk of damage to the cycle, its systems, the environment, other people and their property 2. be able to use relevant sources of information when removing and replacing cycle advanced headsets and bearings 1.5 explain the importance of working to agreed timescales and keeping others informed of progress 2.1 ensure that records for removing and replacing cycle advanced headsets and bearings are accurate 2.2 state the importance of following correct technical data when removing and replacing cycle advanced headsets and bearings 2.3 find and interpret manufacturer s instructions 3. know and understand cycle advanced headsets and bearings 3.1 explain how to distinguish between headsets using SHIS (Standard Headset Identification System) 3.2 state the component parts which make up a threadless headset 3.3 explain the difference between a radially loaded bearing and an axially loaded bearing 3.4 describe how to measure the stem diameter, the different diameters available and their applications 28

4. be able to select and use the appropriate tools and equipment to remove and replace cycle advanced headset and bearings 5. be able to remove, inspect, replace and adjust cycle advanced headset and bearings 4.1 demonstrate how to prepare and use all the equipment required to remove, replace and adjust cycle advanced headset and bearings 5.1 accurately measure the advanced cycle head tube internal and external diameter 5.2 accurately measure the advanced headset bearing size and angle 5.3 accurately measure the fork steerers size 5.4 accurately measure the crown race size 5.5 demonstrate the correct procedure for checking correct fitment and adjustment of an advanced cycle headset and bearing to the manufacturer s specification 5.6 identify and rectify faults presented on cycle advanced headset and bearings 5.7 identify and report damaged or faulty cycle advanced headset and bearings or component parts to the relevant person(s) 6. know how to carry out a quality check on a cycle advanced headset and bearings following removal and replacement activities 6.1 state the quality check process following the removal and replacement activity 6.2 explain how to report any faults identified during the quality check 6.3 describe the process for rectifying any faults highlighted during the quality check 7. be able to carry out a quality check on the cycle advanced headset and bearings following the removal and replacement activity 7.1 assess the condition of the cycle advanced headset and bearings following the removal and replacement activity to include: a. cleanliness b. security of all component parts c. adjustment of headset bearings 7.2 ensure the cycle is returned to the customer in a roadworthy and clean condition 7.3 accurately complete all documentation and pass it to the relevant person(s) 29

Content: Sources of information a. Manufacturer s instructions from distributors and websites b. Specific brand maintenance requirements c. Servicing criteria d. M-Check or check list e. EN14764 f. The Pedal Bicycles (Safety) Regulations 2010 g. Test riding h. Safety equipment i. BS EN Standards i. BS EN 14764 City and trekking bicycles safety requirements and test methods ii. BS EN 14765 Bicycles for young children safety requirements and test methods iii. BS EN 14766 Mountain bicycles safety requirements and test methods iv. BS EN 14781 Racing bicycles safety requirements and test methods v. BS EN 15194 Electrically power assisted cycles Threadless (Aheadset) headset component parts a. Crown race b. Bearing race (upper and lower) c. Bearing retainer ring (upper and lower) d. Lower fixed bearing cup e. Upper fixed bearing cup f. Bearing cover g. Stem h. Spacer and compression ring i. Top cap j. Adjusting bolt Adjustments a. Headset and bearings b. Stem alignment Tools and equipment a. Hand tools b. Measuring equipment c. Bench mounted equipment d. Cleaning and degreasing equipment 30

Evidence Requirements You must: 1. produce evidence to show you meet all of the Learning Outcomes. 2. produce performance evidence resulting from work you have carried out in your training workshop as managed and organised by an approved centre. 3. be observed by an assessor. 1. You must be observed by your assessor successfully carrying out all of the activities listed below on at least 1 occasion. Evidence Ref: a. remove and strip an advanced cycle headset and bearings b. inspect upper and lower bearing race for serviceability c. measure the head tube internal and external diameter d. measure the headset bearing size and angle e. replace and lubricate an advanced cycle headset and bearings f. correctly adjust advanced cycle headset and bearings to manufacturer s specification 2. You must be observed by your assessor successfully carrying out a quality check covering all of the areas listed below. Evidence Ref: a. cleanliness b. security of component parts c. adjustment of headset and bearings Assessor Signature: Pin No: Date: 31

UNIT REF: BC27 UNIT TITLE: REFURBISH CYCLE BOTTOM BRACKETS AND CRANKS Level: 3 Credit Value: 1 GLH: 5 Rationale: The aim of this unit is to provide the learner with the skills and knowledge required to refurbish cycle bottom brackets and cranks. This unit also includes carrying out a quality check on the completed work before returning the cycle to the customer. LEARNING OUTCOMES The Learner will: 1. be able to work efficiently and safely refurbishing cycle bottom brackets and cranks ASSESSMENT CRITERIA The Learner can: 1.1 use appropriate Personal Protective Equipment and safety methods when refurbishing cycle bottom brackets and cranks 1.2 demonstrate Health and Safety workplace procedures when refurbishing cycle bottom brackets and cranks 1.3 demonstrate and describe workplace and legislative procedures for handling, disposal and recycling of used and waste materials 1.4 work minimising the risk of damage to the cycle, its systems, the environment, other people and their property 2. be able to use relevant sources of information when refurbishing cycle bottom brackets and cranks 1.5 explain the importance of working to agreed timescales and keeping others informed of progress 2.1 ensure that records for refurbishing cycle bottom brackets and cranks are accurate 2.2 state the importance of following correct technical data when refurbishing cycle bottom brackets and cranks 2.3 find and interpret manufacturer s instructions 3. know and understand cycle bottom brackets and cranks 3.1 state the alternative bottom brackets available and how their designs differ from the conventional threaded bottom brackets 3.2 identify the advantages and disadvantages of the alternative bottom brackets, including compatibility 3.3 explain how to check the condition of a cycle bottom bracket and crank 32

4. know how to refurbish a cycle bottom bracket and cranks 4.1 explain the limits of refurbishment for cycle bottom brackets to include: a. BB90/95 b. BB 30 c. Shimano Press Fit d. PF30 4.2 explain the limits of refurbishment for cycle cranks 4.3 explain the limits of refurbishment for cycle chainrings 5. be able to select and use the appropriate tools and equipment to refurbish cycle bottom brackets and cranks 6. be able to refurbish a cycle bottom bracket and cranks 5.1 demonstrate how to prepare and use all the equipment required to refurbish cycle bottom brackets and cranks 6.1 demonstrate the correct procedure for inspecting and diagnosing cycle bottom brackets and cranks 6.2 assess the serviceability of cycle bottom brackets and cranks 6.3 identify and rectify faults presented on cycle bottom brackets and cranks 6.4 identify and report damaged or faulty cycle bottom brackets, bottom bracket shells or cranks to the relevant person(s) 7. know how to carry out a quality check on a cycle bottom bracket and cranks following a refurbishment activity 7.1 state the quality check process following the refurbishment activity 7.2 explain how to report any faults identified during the quality check 7.3 describe the process for rectifying any faults highlighted during the quality check 8. be able to carry out a quality check on the cycle bottom bracket and cranks following a refurbishment activity 8.1 assess the condition of the cycle bottom bracket and cranks following the refurbishment activity to include: a. cleanliness b. security of all component parts c. adjustment of bottom bracket d. abnormal noise 8.2 ensure the cycle is returned to the customer in a roadworthy and clean condition 8.3 accurately complete all documentation and pass it to the relevant person(s) 33