Pre-delivery inspection

The pre-delivery inspection (PDI) is the work a dealer or workshop does between receiving a new bike and handing it to the customer: unpacking, assembly, setting up, checking every system and a test ride. Poor assembly causes crashes and warranty claims. This checklist modernises the MAVCC assembly and pre-delivery unit for today's bikes: fuel injection, sealed batteries, tubeless tyres, LED lights, CBS and ABS, and electric bikes. Follow the maker's assembly manual and checklist for the model first; use this page to make sure nothing is missed.

Safety

• Crates are heavy. Lift with equipment or a helper, and lower a crate on a forklift as soon as it clears the truck. Crate nails and metal straps are sharp; box knives can cut the bike and you.
• Keep the bike supported as straps come off.
• Fuel: fill outside or with good ventilation, no flames, extinguisher nearby.
• Batteries: wear eye protection. Fit positive cable first, negative last.

1. Receive and record

1. Inspect the crate on arrival. Report any damage before signing for delivery.
2. Check the frame number (VIN) and engine number on the bike match the papers. K-Light 125: VIN on the frame, engine number stamped on the crankcase (PDF p. 11).
3. Check for open recalls or service campaigns for that VIN with the importer.

2. Uncrate and assemble

1. Remove the top and sides carefully. Check the parts packages against the manual's list.
2. Fit the front wheel and handlebar early so the bike is stable. Leave protective covers on paint until finished.
3. Lay each fastener packet next to where it goes. Work front to rear. Tick each item on the checklist as you finish it.
4. Tighten every fastener to the manual's value with a torque wrench. Fit new split pins and bend them over.
5. Read every Warning (injury), Caution (damage) and Note in the assembly manual. Ask a senior technician when unsure.

3. Prepare

1. Battery: sealed batteries are activated or charged as the battery maker says. Check voltage before fitting (Test and charge a 12 V battery). Route the vent tube, if fitted, away from the chain and frame.
2. Fluids: engine oil level (Check the engine oil level), brake fluid (Check brake fluid level and condition), coolant if liquid-cooled (Check and top up coolant), scooter final drive oil (Change scooter final drive oil).
3. Fuel: add a few litres. On fuel-injected bikes, turn the key on and listen for the pump to run briefly.
4. Tyres: set cold pressures (Check tyre pressure); K-Light 125: front 190 ± 10 kPa, rear 210 ± 10 kPa. Check valves and direction arrows.
5. Wheels and axles: torque, split pins, spokes (Check and tighten spokes).
6. Brakes: lever and pedal free play, firm feel, no drag (Check for brake drag). Check CBS or ABS function as the maker says (Check a combined braking system, Diagnose an ABS warning light).
7. Cables: throttle, clutch, choke at full left, full right and centre (Adjust throttle free play, Adjust clutch lever free play). Throttle snaps shut at every position.
8. Chain or belt: slack and lubrication (Check and adjust chain slack).
9. Electrics: headlight high and low, aim (Aim the headlight), tail and brake lights from both controls, indicators, horn, instruments, warning lights self-test and go out. LED indicators flash at the right rate.
10. Interlocks: side stand switch, clutch switch, neutral light (Test the side stand, clutch and neutral switches).
11. Mirrors, levers, footpegs, stands: adjusted and tight (Check chassis fasteners).
12. Exhaust: wipe off all anti-corrosion spray before the first start, or it burns on as a permanent stain.
13. Fuel-injected bikes: read for stored fault codes (Read engine fault codes) and fit any software update the maker has issued.

4. First start and test ride

1. Start the engine and let it idle. Do not rev a new engine. If it will not start, stop cranking and find out why.
2. Check for leaks and listen for exhaust leaks and odd noises.
3. Test ride wearing a helmet and protective clothing. Check brakes first, at low speed. New tyres are slippery: no hard braking or lean. Do not over-rev. A test ride is not a speed test. (Road test to diagnose a fault.)
4. After the ride, recheck for leaks, chain slack and fasteners. Wipe the bike down.

5. Hand over to the customer

• Keys (count them), tool kit, owner's manual, warranty papers and registration.
• Explain the controls, the stands, fuel type, tyre pressures, the running-in rules in the manual and the first service. K-Light 125: first service at 300 km (PDF p. 51).
• Show the customer the Pre-ride check.

Electric bikes: add these

• Make sure you know the maker's high-voltage safety rules before working near the pack (Make an electric motorcycle safe to work on).
• Battery charge level and health (Check battery state and health), charger and cable (Check the charger and cable), charge port (Inspect the charge port and plug).
• Error codes and firmware version (Read electric drive error codes).
• Throttle, brake and stand interlocks (Check the throttle, brake and stand interlocks), regenerative braking (Check regenerative braking), 12 V system (Check the 12 V auxiliary system).
• Swap batteries: latch and contacts (Check swap battery contacts and latch).
• Explain charging, storage and range to the customer (Store an electric motorcycle).

Sign-off

Every checklist line must be ticked YES before delivery. A NO is fixed and rechecked, not skipped. The technician and a second person sign and date the sheet.