ONE-DAY WORKSHOP CURRICULUM

As of October 2011, more than 10,500 people have attended our one-day workshop and gotten a bike for 'half the regular Accra price'. The workshop has been given more than 500 times.  In Sierra Leone, since 2010, more than 200 people have attended a similar program, enjoying a similar discount. 

A sound half-priced mountain bike is $19, skinny tires are $17, kids' bikes $9. In the far distant reaches of the country people pay the same as near the port despite transport costs which reach up to $1700.

The main point of the workshops is to introduce people to the idea of maintenance and so they become aware of small problems before they become big ones. Essentially, our mantra is, "if you have the small problem repaired before it can become a big problem, you will save money in your pocket," Our lead trainer George says it again and again during the workshop.
One of our workshop hosts, a Peace Corps volunteer named Tonya made this point, "Some people didn't realize that you can fix your bike yourself, especially punctures. Some were saying they used to take it to a repairer and pay 2000-5000 cedis, (22-55 cents). Now they can just fix it themselves."
Essential to the workshops is the 'practicals', when everyone gets a chance to actually practice the repairs we teach through hands-on learning is.
                                                                                     

VILLAGE BICYCLE PROJECT ONE-DAY REPAIR WORKSHOP OUTLINE 

This curriculum is what we want all adult students to learn.  For some it will be difficult, and others will already know plenty.  So you as teachers must watch your students, to see how they learn.  If you see they know plenty, then you can add things to the program.  If they don’t understand, you have to try more.   

Practicals:

We are now doing the practicals in groups of two people with two bikes.

We need to have enough tools for every group of two to have its own tools.  The tools list is on the next page.

Practicals are very important for learning.  They also help keep people awake.  So we do them often.  Do not allow 45 minutes to pass without a practical. 

Tools for Practicals:

Tools for practical should not be the same as tools that are used to prepare the bicycles.  These tools should be held back for practicals so that the spanners do not get lost and they remain in good condition so that they are easy for beginners. 

Tools for Prizes:

Bring one pump and two cold patch kits for each workshop to give as prizes to the best participants.  Throughout the workshop you will watch for those who are trying hard, mastering the material or helping others learn.  At the end you can award these people with a pump or a cold patch.  In a workshop where nobody tries, you do not have to award anything.  You can award more than three people if you think it is a good idea.  It is up to you. 

Before Leaving Accra:

Load up all these for demonstration:

A screw top bottle                             Spoiled tube and tire from under inflation

 Spoiled nuts                                      Tire spoiled by brakes

Bearing sets to show         

                                   

Also:    10 punctured tubes

 Tools for villages and repairers: Be sure you know the number of communities receiving community tools and be sure you have all.  Estimate the number of repairers receiving tools. 

 Before the program:

  • Arrange the chairs in a semi-circle, so that some people can see the person across from them. 
  • Arrange the bicycles in groups of two.
  • Every pair of bicycles should have at least one bicycle with racer brakes, so the brake shoes can be easily adjusted with 10 spanner.
  • Have a local bicycle to use for showing common problems. 

Riding Test:

When you reach the village, make sure that all participants know how to ride.  Prepare a bicycle to test them if necessary.  You can test them before the workshop starts by letting them ride one of the bicycles a short distance.  When in doubt, test the person.  If someone is not able to ride, they should not be at the workshop.  The person who will be using the bicycle should come to the workshop.  

                                  WORKSHOP TOOLS LIST

 

TOOL                                       

QUANTITY

TOOLS FOR PRACTICALS

10 spanner

10

13 spanner

10

14 spanner

5

15 spanner

10

Iron brush

10

Sandpaper

20

Solution

3

Tire levers

12 (6 pair) 

Pumps

10

Patches

15 per workshop

Tubes with puncture

10

Rags

10

REPAIRER TOOLS

FR-1

1 per repairer

FR-4 or 5

1 per repairer

Chain tool

1 per repairer

Crank puller

1 per repairer

Headset spanner

1 per repairer

8-9-10 box spanner

1 per repairer

4-5-6 allen key

1 per repairer

Cone spanner

1 per repairer

Tire levers

2 per repairer

COMMUNITY TOOLS

Pump

1 per village

Shifting spanner

1 per village

Spanner set

1 per village

Screwdriver

1 per village

4-5-6 allen key

1 per village

Machine oil

1 per village

Cold patch

1 per village

Gas pliers

1 per village

Tire levers

2 per village

TOOLS FOR PRIZES

Pumps

1 per workshop

Cold patch

2 per workshop

 

VILLAGE BICYCLE PROJECT ONE-DAY WORKSHOP OUTLINE

Copies available – GH 20p per page or email ghanabikes@yahoo.com

 

INTRODUCTION TO WORKSHOP:

  1. 1.     Introduce instructors and translator.
  2. 2.     Rules and Expectations:
  • Everyone must be able to ride a bicycle to be a part of the workshop. 
  • If you’re not on time for the workshop and after the lunch break then you can be sacked. 
  • Bicycles are chosen at the end of the workshop.  The way they are chosen is decided by the organizer.   
  • You must participate actively in the workshop or you will not receive a bicycle. 
  • You cannot leave without asking permission from the instructor.
  • Does anyone have any questions about the rules?
  1. 3.     Why do we have workshops instead of just selling bicycles?  Ask the class if they know why before telling them why.
  • If you give someone a bicycle today, tomorrow when it spoils, the person will come back to you for another bicycle.  But if you teach someone to repair, when the bicycle spoils they will know what to do do fix the problem.
  • A small problem will take some time and maybe some money to repair.  But if you leave a problem until it becomes big it will cost more money to repair or it may completely spoil your bicycle. 
  1. 4.     If the workshop is a women’s workshop, discuss why we have all women workshops.  Ask the class if they know why before telling them why.
  • We want to have a place where women feel free and can work together to learn about their bicycles.  Women are less free when men are around.
  1. 5.     Workshop goals: 
  • To know when you have a small problem so that it can be repaired before it becomes a big problem.
  • To know how to use tools to make basic repairs and adjustments. 
  1. 6.     Workshop outline:
  • Introduction to tools
  • Removing the front wheel
  • Tires and punctures
  • Rotational Systems
  • Chain
  • Brakes
  • Gears and Selectors
  • Size and Safety
  • Choosing of bicycles

INTRODUCTION TO TOOLS:

  1. 1.     Preparation: 
  • Have damaged nuts ready to show the class. 
  • Organize the bicycles in groups of two. 
  • Note which bicycles have allen key steer poles and which have 13mm steer poles.  Prepare the proper tools for each bicycle so that each pair of bicycles has its own tools.
  1. 2.     How many people in the class have used tools before? 
  • Let them come and show the tools they have used and tell what they used tools for.
  • How many have used gears before?  Repaired a puncture?
  1. 3.     What other tools are common for the bicycle?
  • Have them say the names of the tools or point to them.
  • Help them to see where on the bicycle each tool is used.
  • Make sure they know the basic tools:
    • Spanner, shifting spanner, screwdriver, allen key, pliers.

 4.     Spanner use:

  • Let the class look at the damaged nuts and ask them what happened to the nuts.
  • Proper size is best.  The spanner must sit well on the nut. 
  • Use a shifting spanner to show how to not fix the spanner on the nut.  Use a chalkboard to draw pictures if you can.

 

  1. 5.     Tightening and loosening a nut.
  • Use different methods to explain how to tighten and loosen.
  • Demonstrate with the oil bottle
  • Demonstrate by turning yourself.

 

  1. 6.     PRACTICAL: Straightening steer pole.
  • Show the group how to straighten steer pole.
  • Show and explain maximum extension marks.
  • Explain why it’s important to tighten the nut after straightening.
  • Make sure they understand how the allen key works.
  • Give each pair of people one tool (either allen key or 13 spanner) and send them to a pair of bicycles to straighten the steer pole.
  • When the steer poles are straight, check each one to see if they tightened the nut enough.  If not, make them tighten it more.  If they are finished they can go and sit down.

 

REMOVING THE FRONT WHEEL

  1. 1.     Preparation
  • Make a note of which bicycles have 13 and 14 nuts and quick release to help with the practical.
  • Let someone come and remove the nuts on the front wheel. 
  • Discuss order of washers, mud guard, basket, etc. 
  • Discuss removing the brake shoe and disconnecting the brake.
  • Let some people come to disconnect and reconnect the brake.
  • Explain the use of quick release.   You do not need tools for this.

 

  1. Fixing back the front wheel.
  • Where do the washers go?
  • Where do mud guards go?
  • Do not tighten one side completely before going to the other side. 
  • How to make sure the wheel is straight.
  • What happens if we don’t make the nuts tight enough?
  • Reconnecting the brake.

 

  1. PRACTICAL:  Removing and fixing back the front wheel.
  • Put the bicycles in groups of two and provide each pair of people with the appropriate tool for their bicycle.
  • Let them remove the front wheel. 
  • Once they have removed the wheel and an instructor has seen it, let them fix it back.
  • Check all wheels to make sure washers and accessories are in the correct order.  If they are not, have person re-do it correctly.
  • After practical check all nuts to make sure they are adequately tight.

 

  1. 4.      REVIEW: What have we learned?  Are there any questions?

 

 

TIRES AND PUNCTURES

  1. 1.     Preparation:
  • Prepare tire damaged by not enough air, 10 punctured tubes, basin of water, remove 5 front wheels from bicycles for the second practical.

 

  1. 2.     Inflating the tires.
  • Why is proper inflation important?
  • Show tire damaged by not enough air.  Pass it from person to person.
  • How do we know when there is enough air in the tire?
  • Show them different types of valve (local, “presta” and car valve)
  • Show them how to fix the pump on the valve.
  • Show them pumping tire to proper amount.

 

  1. 3.     PRACTICAL:  Pumping
  • Put the bicycles in groups of two.
  • Let each pair of people take a pump and pump their tires. 
  • If they find a puncture they should show an instructor.

 

  1. 4.     Removing the tube from the tire.
  • If there was a puncture in the practical, use that wheel for teaching.
  • Why don’t we use screwdrivers?
  • What can you use if you don’t have tire levers?  Bend a spare spoke.
  • Start opposite the valve—emphasize this several times.

 

  1. 5.     Finding and repairing the puncture.
  • After removing the tube, let someone pump it.
  • What are different ways to find a puncture?  Let them answer.
    • Hear it
    • Feel it with your hand or face
    • Use basin of water
    • Put it in fine sand
  • Why do we use sandpaper on the puncture?  Let them answer.
  • Importance of scrubbing a large area.
  • Do not put the solution on too thick.
  • While the solution dries, let someone check the tire for what caused the puncture.
  • Put the patch on with your hands—don’t hammer it!
  • Check for more punctures before fixing it back to the bicycle.

 

  1. 6.     Fixing the tube back in the tire.
  • Show them how to fix the tube and tire back on the rim.
  • Explain why it is important to straighten the valve.
  • Let them also try fixing the tube back in the tire.  Let them help each other.

 

  1. 7.     PRACTICAL: Removing and fixing back the tube.
  • Make groups of 4 people and give them each a wheel, 2 tire levers and a pump. 
  • If possible, give them wheels that have punctures. 
  • Each group will remove the tube from the tire and fix it back.
  • If there is a puncture they will fix it.
  • Instructors will help apply solution and make sure that every person in each group is involved in the practical.
  • Give those who did not have a puncture a punctured tube to patch.
  • Those who finish early can fix the wheels back on their bicycles.

 

  1. 8.     PRACTICAL:  Fixing a puncture
  • Make sure every two people has 1 tube to patch.
  • Give everyone a pump. 
  • As each group finds the hole in the tube, give them a piece of sandpaper.
  • As each group finishes with the sandpaper, help them apply the solution.
  • When they think the solution is dry, check it and if it is try give them a patch.
  • When they finish patching, let them pump to see if they have patched well.
  • *Do not remove patches from tubes after the practical.  Give the tubes new punctures for the next class.  It is difficult for beginners to patch a tube well in a place that was already patched.*

 

  1. 9.     REVIEW: What have we learned?  Are there any questions?

 

 

BEARINGS:

  1. 1.     Preparation:
  • Find a bicycle that has some loose bearings for demonstration.
  • Have some bearings sets available to show the class.

 

  1. 2.     What are bearings and what do they do?
  • Show the class the bearings and ask them to point to the 4 places on the bicycle where we find bearings.
  • What do all of these places have in common? (they move/rotate turn against each other, inside to outside)
  • If your bearings spoil, what happens to these places on the bicycle?
  • How do we know when our bearings are starting to spoil?
  • It is fast and cheap to fix bearings when they are just starting to get loose, but if you leave them shaking for a long time you will spend a lot of money replacing the small pieces inside before you can ride your bike again.

 

  1. 3.     How to check your bearings.
  • You can check your bicycle for shaking bearings and save money.
  • Show them how to check the 4 places.
  • Organize an example of a loose wheel and an okay wheel and have everyone feel the difference. 
  • If you find a problem, take it to the fitter early.
  • If you wash your bike, take care not to put water inside the bearings.

 

  1. 4.     PRACTICAL: Checking the bearings.
  • Everyone will go to a bicycle and check the bearings.
  • If they find a problem now, call an instructor and we will fix it for you.
  • Instructors should make sure that everyone is properly checking all 4 places on the bicycle.

 

  1. 5.     REVIEW: What have we learned?  Are there any questions?

 

 

CHAIN MAINTENANCE

  1. 1.     Preparation:
  • Find a bicycle with a dirty chain and a bicycle with a dry chain to use as examples.
  • Prepare 10 iron brushes and 10 rags for the practical.
  1. 2.     Dry chain
  • How did the chain become dry?  (rain, dust, too long without oil)
  • To fix the chain we have to use three things—rag, oil and brush. 
  • What do we use first?
  • Let someone come and clean the chain with the iron brush.
  • What kinds of oil are good for the chain?  Let the class answer and discuss.
  • Why do we clean the chain with a rag after applying oil?
  • Show them how to hold the rag.  Let someone come and try it.
  • If you don’t use the rag, your chain will become like the dirty, oily chain.

 

 

  1. Dirty, oily chain.
  • What should we do to help the dirty chain? 
  • Let them discuss.
  • Why do we not add oil?

 

  1. 4.     Importance of chain maintenance.
  • A dry or dirty chain will spoil earlier. 
  • It will also wear out everything it touches.
  • What parts of the bicycle are damaged by a poorly maintained chain?  Let someone come and point to the places on the bicycle.
  • Chainring, selector, free.

 

  1. 5.     PRACTICAL:  Cleaning your chain.
  • Each pair of people will examine the chains of their bicycles and use the iron brush to clean them.
  • If they need oil, they will call an instructor who will help them oil it.
  • After oiling, clean with a rag.

 

  1. 6.     REVIEW: What have we learned?  Are there any questions?

 

 

BRAKES

  1. 1.     Preparation:
  • Make sure bicycles are organized so bicycles with cantilever brakes are with bicycles with caliper/racer brakes.
  • Go around and make brake pads on all bicycles with caliper/racer brakes rub tires or be off the rim.

 

  1. 2.     What part of the bicycle is the brake?
  • Let people come and show you parts of the brake.
  • The brake is made up of many parts!
  • Your hand pulls the brake lever and that makes the brake pads touch the rim.

 

  1. 3.     Common problems with the brakes.
  • Brakes are too soft.  The lever should not touch the handlebar.
  • Brake pads should touch squarely on the rim.
  • What happens if they rub the tire?  (show example)
  • Brake pads should not rub the rim when you are not using them.
  • Use a 10 spanner to adjust brake pads that are not fixed well.
  • Brakes are too hard.  Show how to add oil.

 

  1. 4.     PRACTICAL:  Checking and adjusting brakes.
  • Put the bicycles in groups of two and give each pair of people a 10 spanner.
  • Let them check and adjust the alignment of their brake pads.
  • Let them check how soft or hard the brake levers are.
  • Do the cables need oil?
  • Instructors should help each group manage the different types of brakes.

 

  1. 5.     REVIEW: What have we learned?  Are there any questions?

 

 

GEARS AND SELECTORS

  1. 1.     Preparation:
  • Put bicycles in groups of two. 
  • Bring bicycles with different types of gear levers.

 

  1. 2.     What are gears?
  • How many people have used gears before?
  • Where are the gears on the bicycle?  Let them come and point to the chainrings, free, selector and gear levers. 
  • Like the brakes, the gears are made up of many parts.
  • What do the gears help us to do?
    • Run fast on flat or down hill
    • Go up hills more easily.

 

  1. 3.     Using the gears:
  • Don’t worry about the gears in the front.  You can learn them later if you want. 
  • Which of the back gears is for running fast?  Let them answer.
  • Which of the back gears is for climbing hills?  Let them answer.

 

  1. 4.     How do we change the gears?
  • Most important thing is to PEDAL while you are changing them.  If you don’t pedal, nothing will happen.
  • You have to pedal FORWARD.  Pedaling backward while shifting can spoil the selector.
  • Never force the pedals if they don’t turn easily.  You will spoil the selector.
  • Let someone come and shift to the soft gears while you hold the back tire up.
  • Let someone else come and shift to the hard gears.
  • Make sure everyone can see the chain moving as they shift.
  • Let someone come and try a different type of gear lever.
  • Explain the different gear levers to everyone.

 

  1. 5.     PRACTICAL:  Changing the gears.
  • Let them work in pairs. 
  • One person will hold the back tire off the ground while the other pedals and shifts from the soft gears to the hard gears. 
  • They will try to reach all the gears.  If they cannot, or the chain falls off, call the instructor to adjust the selectors.
  • Make sure both people shift both bicycles.
  • Instructors should be helping each group understand their gear levers, pedal forward and successfully shift the gears.

 

  1. 6.     REVIEW: What have we learned?  Are there any questions?

 

 

BICYCLE SIZE AND SAFETY

 

  1. 1.     Size.
  1.  
    • Review maximum extension points for seat and steer posts
    • Have someone come up and figure out how to loosen and adjust the steer and seat poles.  Have them explain it to the class. 
    • Talk about the height of the cross bar (optional)

 

  1. 2.      Safety.
  • Hazards: thick sand, glass, gravel.
  • People often cannot hear you when you’re coming from behind.
  • Give way to those who are footing and carrying a load
  • Discuss what happens when you loan your bicycle to other people.

 

  1. Maintenance
  • Washing your bike.  Take care to keep water out of the bearings
  • Where can you find good repairs and spare parts?  (see below)
  1. 4.     REVIEW: What have we learned?  Are there any questions?