Motor Cycle Mechanic 1

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Francis Hampton
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1 Motor Cycle Mechanic 1 Training Objective: Motor Cycle is a popular use in urban as well as rural areas throughout the country. This course aims at producing semi skilled workers who can carryout minor repairing of Motor Cycle (both & 4 Stroke) Curriculum Salient: i. Entrylevel Middle ii. Total duration of course Months iii. Total training hours 60 Hours, iv. Training methodology 90% Practical 10% Theory v. Medium of instruction Urdu / English

2 Motor Cycle Mechanic Skill Proficiency Detail: At the end of the course the trainees must be able to: 1. Use, handle workshop tools, equipments efficiently and above safety measures.. Remove dismantle inspect, refit install engine, parts i.e. came shaft and cylinder bore etc.. Set the valve timing of 4 stroke motorcycle. 4. Remove / inspect service and oil pump of motor cycle ( stroke & 4 stroke) 5. Set the ignition timing (C.B Point adjustment) and check with ignition timing light. 6. Remove / Inspect and refit clutch plates and make adjustment. 7. Remove, inspect and refit transmission system of the bike. 8. Remove inspect and refit brake shoes / disk pads 9. Remove inspect & refit front & rear shock absorbers. 10. Tune up the motor cycle (stroke & 4stroke).

3 Motor Cycle Mechanic Knowledge Proficiency Detail: On successful completion of the course the trainee should have knowledge of : 1. Common hand tools / measuring tools. Internal combustion engine and External combustion Engines. Four stroke and two stoke engines of motor bikes / scooters. 4. Fuel system of motor cycle (4stroke) 5. Ignition system parts (point & CDI system) 6. Lubrication System 7. Cooling system (Air Cooling) 8. Mechanical & Hydraulic Brake System. 9. Suspension System / Shock absorbers.

4 Motor Cycle Mechanic 4 Scheme of Studies ( Months Motor Cycle Mechanic Course) Sr. No Topic Theory Hours Practice Hours 1. Auto work shop safety precaution / safety riding 6. Introduction of work shop tools & uses 40. History of motor cycle & 4 stroke Introduction of the Internal and external; combustion engine. Introduction of workshop equipment / special tools and their uses. Introduction of main motor cycle parts with the help of parts catalouge consolation of service manual / Data book Working of 4 stroke motor cycle engine Working of stroke motor cycle engine and comparision of stroke and 4 stroke motor cycle engine Introduction & working principal if fuel system and venturi effect Introduction of Fuel system part Replacement of chain sprocket set Introduction & working principle of Ignition system and parts Ignition System Introduction of lubrication system Lubrication system Introduction to cooling system Introduction of transmission & clutch 18. Introduction / working of clutch mechanism Introduction / working of transmission 0 0. Working function of starting system. 15

5 Motor Cycle Mechanic 5 1. Principle & introduction of brake system. Brake system 15. Principle & introduction & suspension system 4. Suspension system (front / rear) Battery Charging system Motor cycle tuning procedure Top over hauling procedure 0 9. Complete engine overhauling procedure 0 0. Fault finding & their remedy 0 REVIEW TOTAL 6 4 Grand Total 60

6 Motor Cycle Mechanic 6 Detail of Course Contents (Months Motor Cycle Mechanic Course) Sr. No Topic Theory Practical 1. Auto workshop safety precaution / safety riding 6. Introduction of workshop tools & their uses. a. Fitting tools & their uses b. Measuring tools & measuring exercise c. Marking tools & their uses d. Cutting tools & cutting exercise e. Filing exercise f. Drilling exercise g. Threading exercise h. Extraction exercise History of motor bike specially 4 strokes and strokes 0 4. Introduction of internal combustion engine and external combustion engine Introduction of workshop equipment / special tools and their users. a. Use of magnet puller b. Use of timing tester. c. Use of timing Gun/buzzer d. Use of digital tachometer e. Use if dial indicator tester f. Use of multi tester g. Use of tachometer h. Use of timing gear removing puller and refitting tools i. Use of magnet base plate. Pullar j. Use of valve compressor etc. 6. Introduction of main motor cycle parts with the help of parts Catalogue, consultation of service manuals / data books

7 Motor Cycle Mechanic 7 a. Catalogue study / data books b. Body parts removal / refitting c. Engine parts & their uses Working of Motor cycle engine a. Working of 4stroke motorcycle engine. b. Working of two stroke engine Comparison of stroke and 4stroke engine 9. Introduction & working principal of fuel system & venturi effect Fuel system a) Service of fuel filter. b) Carburetor purpose and type / service c) Fuel level adjustment in carburetor d) Setting of air fuel ratio w.r.t speed Manually With exhaust gas analizer e) Air fuel ratio setting of air fuel ratio w.r.t speed f) Air, fuel mixture adjustment g) Needle adjustment (selection of needle groove) h) Changing / replacement of needle / jet i) Throttle fitting j) Measurement of jet size Replacement of chain sprockets set 1. Introduction & working principle of ignition system & parts 4 1. Ignition System. a) C.B point adjustment b) Checking of magnet ignition system c) Testing of coil ignition system parts d) Spark plug testing w.r.t colour / physical condition e) Checking of C.D.I system f) Checking of pulsar coil resistance g) Checking of ignition coil 1 1

8 Motor Cycle Mechanic 8 h) Checking of condenser. 14. Introduction of lubrication system 4 15 Checking of lubrication system a) Inspection of oil pump b) Oil changing procedure c) Checking & cleaning of oil strainer / fitter d) Oil passages cleaning e) Introduction of engine oil with grade f) Checking of oil level g) Inspection of oil seal/replacement. 16 Introduction of cooling system & main parts of system 17 Introduction of transmission & clutch 18 Introduction working of clutch mechanism with the help of training model / motorcycle. a) Adjustment of clutch free play b) Changing of clutch plates c) Checking of pressure plate. d) Inspection / checking of spring (free length) e) Clutch cable/ wire replacement / checking 19 Working of Transmission with the help of training model / motorcycle engine. a) Removing of transmission b) Inspection of gears/ washers c) Refitting & reassembling of transmission Working / functioning of starting system. a) Kick and spindle replacement. b) Introduction of self starter system 15 1 Principle & introduction of brake system.. Brake System a) Checking of brake mechanism b) Checking of Disc brake

9 Motor Cycle Mechanic 9 c) Brake shoe replacement d) Brake adjustment e) Replacement of rubber pads f) Replacement of wheel bearing. Principle and introduction of Suspension System. 4. Suspension System (Front / Rear) a) Inspection of front fork suspension (shock absorber) b) Maintenance / service of front shock absorber c) Replacement of handle ball & cap. 5. Battery a) Checking (electrolyte level / gravity) b) Charging c) Preparation of electrolyte Charging system a) Inspection of charging system 5 7. Motor cycle Tuning Top Over Hauling a) Inspection of valve timing gears/ sprocket and their setting 0 9. Complete engine overhauling 0 0. Fault finding and their remedy 0 Review 10 Total 6 4

10 Motor Cycle Mechanic 10 List of Tools / Equipment (For a Class of 5 Students) Sr. No List of Tools / Equipment Quantity 1. Tool box (trolley type) 1 Nos. Steel foot rule 6 1 Nos. Steel foot rule 1 1 Nos 4. Venire caliper o to 160 mm 1 Nos 5. Feeler gauge 1 Nos 6. Screw driver flat tips size mm 1 Nos 7. Screw drive flat size 7 mm 1 Nos 8. Screw drive flat tip size 4 mm No.1 1 Nos 9. Screw driver Philips No. 1 Nos 10. Screw drive Phillips No. 1 Nos 11. Screw drive Phillips 1 Nos 1. Stubby screw driver flat 1 Nos 1. Tubby screw drive Phillips 1 Nos 14. File flat 00 mm 1 Nos 15. File flat 00 mm 1 Nos 16. Round file 00 mm 1 Nos 17. Half rounder file 00 mm 1 Nos 18. Allen key set 400 mm 1 Nos 19. Double open end spanner set 6 to mm 1 Nos 0. Off set ring spanner set 6 to mm 1 Nos 1. Open and ring spanner (combination) 6 to mm 1 Nos. Box Spanner Set 1 Nos. Screw wrench adjustable 6 1 Nos

11 Motor Cycle Mechanic Screw wrench adjustable 1 1 Nos 5. Ball pin hammer 50 gm 1 Nos 6. Cross pin hammer 50 gm 1 Nos 7. Combination plier 6 1 Nos 8. Nose plier 6 1 Nos 9. Grip Plier 8 1 Nos 0. Oil can 1 Nos 1. Needle file set (set of 1 pices) 1 Nos. File cleaning brush 1 Nos. Flat chisel 1 Nos 4. Rubber hammer 1 Nos 5. Plastic hammer 1 Nos 6. Hack saw frame 1 1 Nos 7. Socket Set complete 6 to mm (1 side) 1 Nos 8. Socket set complete 6 to mm (6 side) 1 Nos 9. Dial indicator gauge range 50 to 150 mm 05 Nos 40. Micro meatier 0 to 5 mm 05 Nos 41. Micro meatier 5 to 50 mm 05 Nos 4. Micro meatier 50 to 75 mm 05 Nos 4. Tray G1 sheet 18 *4 05 Nos 44. Oil Gun 05 Nos 45. Timing Gun electronic 6 volt & 1 volt 05 Nos 46. Spark plug spanner for different motor cycle special Honda 70, 15, & Yamaha Nos 47. Puller inside 05 Nos 48. Puller out side 05 Nos

12 Motor Cycle Mechanic Torque wrench different type 05 Nos 50. Bench vice (standard size) 1 Nos 51. Work bench 1 Nos 5. Lift / Ramp for motorcycle. 4 Nos 5. Air com pressor 0 Nos 54. Spark plug cleaner & tester 0 Nos 55. Battery charger 6 to 1 volt 0 Nos 56. Air gun duster (pistal type ) 05 Nos 57. Socket handle spanner (TType) 8,9,10,1,14 mm. 05 Nos 58. Impact screw driver set (hammering type ) 05 Nos 59. Motor cycle Honda CD70 0 Nos 60. Motor cycle Honda CG15 0 Nos 61. Motor cycle Yamaha YB Nos 6. Motor cycle Suziki 80CC 0 Nos 6. Engine stroke 05 Nos 64. Engine 4 stroke CD70 05 Nos 65. Engine 4 stroke CG Nos 66. Valve compressor 05 Nos Special Tool 1. HONDA Motorcycle Company tool display board CD 70 & CG 15. (1 Set). YAMAHA Motorcycle Company tool display board. (1 Set). SUZUKI Motorcycle Company tool board. (1 Set)

13 Motor Cycle Mechanic 1 Minimum Qualification For Instructor Diploma of Associate Engineer in auto diesel technology & three years experience in relevant field motorcycle repairing. Twoyear certificate with (Auto Mechanic) with 6year experience in relevant field.

14 Motor Cycle Mechanic 14 Employability of Pass Outs On successful completion of this Course the trainee will be able to work in the following fields: 1. Motor cycle repair shops as a helper mechanic.. Motor cycle sales shops as assembler.. Various Motor cycle production units.

Total duration of course = 3 Months (12 weeks) Total training hours = 400 hrs.

Total duration of course = 3 Months (12 weeks) Total training hours = 400 hrs. 1 TRAINING OBJECTIVES: In order to reduce the unemployment and poverty in the society, the curriculum is designed to impart the technical knowledge and skill to those who are literate and.can not do the