MOTOR CYCLE MECHANIC - Trade Testing Board

GOVERNMENT OF THE PUNJAB

TECHNICAL EDUCATION & VOCATIONAL TRAINING AUTHORITY

CURRICULUMFOR FOR CURRICULUM

MOTOR CYCLE MECHANIC (6 – Months Course)

CURRICULUM SECTION

ACADEMICS DEPARTMENT 96-H, GULBERG-II, LAHORE Ph # 042-9263055-9, 9263064 [email protected], [email protected]

Motor Cycle Mechanic (6-Months Course)

1

TRAINING OBJECTIVES: Motorcycle is a popular vehicle in urban as well as rural area throughout the country and play a vital role in provision of transportation facilities to the community This curriculum is developed keeping in view the requirement of the market demand by more focusing on practical alongwith necessarily required theoretical knowledge alongwith work ethics in order to produce semi skill workers who can carry out minor repairing of both 2 and 4 stroke motorcycles This curriculum covers the most important topics of safety precautions, workshop tools, introduction of engine, special tools, comparison of two & four stroke motor cycle engines, fuel system, liberation system, cooling system starting system, suspension system, charging system, tuning, over hauling ,fault finding and their remedies along with Functional English & work ethics.

CURRICULUM SALIENTS:Name of the course

Motor Cycle Mechanic

Entry Level

Middle

Duration of Course

6 – Months 800 Hours 40 Hours per week 6 days a week 40 hours per week 07 hours per day except Friday 05 hours

Training Methodology

Practical Theory

Medium of Instruction

Urdu / English

90% 10%

Developed by Curriculum Section, Academics Department TEVTA.


2

SKILL PROFICIENCY DETAILS: On successful completion of this course, the trainee should be able to:1.

Use & handle workshop tools, equipments efficiently.

2.

Observe safety measures.

3.

Remove, dismantle, inspect, refit install engine parts i.e. came shaft and cylinder bore etc.

4.

Set the valve timing of 4- stroke motorcycle.

5.

Remove / inspect oil pump of motorcycle (2 stroke & 4 stroke)

6.

Set the ignition timing (CB Point adjustment) and check with ignition timing light.

7.

Remove, inspect and refit clutch plates and make adjustment.

8.

Remove, inspect and refit transmission system of the bike.

9.

Remove, inspect and refit brake shoes / disk pads

10.

Remove, inspect & refit front & rear shock absorbers.

11.

Tune up the motor cycle (2-stroke & 4-stroke).



KNOWLEDGE PROFICIENCY DETAILS: On successful completion of this course, the trainee should be able to:1.

Explain the common hand tools / measuring tools

2.

Explain the internal combustion engine and External combustion Engines

3.

Explain the four strokes and two stoke engines of motor bike / scooter.

4.

Explain the fuel system of motor cycle (4-stroke)

5.

Define the Ignition system parts (point & CDI system)

6.

Define the lubrication System

7.

Explain the cooling system (Air Cooling)

8.

Explain the mechanical & Hydraulic Brake System.

9.

Explicate the suspension System / Shock absorbers.

10.

Explain the tuning of motor cycle.

11.

Explain the overhauling of motor cycle.


3


4

CURRICULUM DELIV ERY STRUCTURE

W E E K

Curriculum Delivery

Revision

Co-curricula Activities

Final Test

1-20

21

22-25

26

Total

26 20

1

4

1



5

SCHEME OF STUDIES Motor Cycle Mechanic (6 – Months Course) Sr. No.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

Main Topics

Auto work shop safety precautions/ safe riding Introduction of work shop tools & uses History of motor cycle( 2 & 4 stroke) Internal and external; combustion engine. Introduction of workshop equipment / special tools and their uses. Introduction of main motor cycle parts with the help of their catalogue consolation of service manual / Data books Working of 4 stroke motor cycle engine comparison of 2 stroke and 4 stroke motor cycle engines Fuel system and venturi effect Fuel system. Replacement of chain sprocket set. Principle of ignition system Ignition System. Introduction of lubrication system Lubrication system Cooling system transmission & clutch Clutch mechanism Introduction / working of transmission Starting system. Principle & introduction of brake system Brake system Principle & introduction or suspension system Suspension System (front / rear) Battery Charging System Tuning procedure Top over hauling procedure Engine overhauling procedure Fault finding & their remedies Functional English Work Ethics TOTAL

Theory Hours

Practical Hours

-

15

5 5

70 -

-

59

Total Hours

15 70 5 5 59 70

-

70

6

-

6

-

8 6 4 3 6 4 -

49 15 34 33 30 46 20 41

7

-

20 -

45 25 10 20 48 35 15 20 20

45 25 10 20 48 35 15 40 20

80

720

800


6 6 8 49 15 6 34 4 33 3 6 30 46 20 4 41 7


6

DETAIL OF COURSE CONTENTS Motor Cycle Mechanic (6 – Months Course) Sr. No 1.

Auto workshop safety precautions / safe riding

2.

Introduction of workshop tools & their uses.

Detail of Topics

Theory

Practical

-

15

2.1

Fitting tools & their uses

-

7

2.2

Measuring tools & measuring exercise

-

15

2.3

Marking tools & their uses

-

4

2.4

Cutting tools & cutting exercise

-

10

2.5

Filing exercise

-

16

2.6

Drilling exercise

-

10

2.7

Threading exercise

-

5

2.8

Extraction exercise

-

3

3.

History of motor cycle (4 strokes and 2 strokes)

5

-

4.

Internal and external combustion engine.

5

-

5.

Introduction of workshop equipment / special tools and their uses. 5.1.

Use of magnet puller

-

6

5.2.

Use of timing tester.

-

6

5.3.

Use of timing Gun/buzzer

-

6

5.4.

Use of digital tachometer

-

6

5.5.

Use of dial indicator tester

-

6

5.6.

Use of multi tester

-

4

5.7.

Use of tachometer

-

6

5.8.

Use of timing gear removing puller and refitting

-

5

-

6

-

8

tools 5.9.

Use of magnet base plate

5.10. Use of valve compressor etc. 6.

Motor cycle parts 6.1.

Catalogue study / data books

10

6.2.

Body parts removal / refitting

30


Motor Cycle Mechanic (6-Months Course) 6.3.

Engine parts & their uses.

7 -

30

7.

Working of 4 Stroke Motor cycle engine 7.1.

Working of 4-stroke motorcycle engine.

3

-

7.2.

Working of two stroke engine

3

-

8.

Comparison of 2-stroke and 4-stroke engine

6

-

9.

Fuel system & venturi effect

8

-

10.

Fuel System 10.1. Intrduction

-

2

10.2. Service of fuel filter.

-

10

10.3. Carburetor purpose and type / service

-

8

10.4. Fuel level adjustment in carburetor

-

7

-

3

10.6. Air, fuel mixture adjustment

-

3

10.7. Needle adjustment (selection of needle groove)

-

8

10.8. Changing / replacement of needle / jet

-

2

10.9. Throttle fitting

-

6

10.5. Setting of air fuel ratio w.r.t speed 10.5.1. Manually 10.5.2. With exhaust gas analyzer

10.10. Measurement of jet size. 11.

Replacement of chain sprockets set

-

15

12.

Introduction & working principle of ignition system

6

-

13.1. C.B point adjustment

-

6

13.2. Checking of magnet ignition system

-

3

13.3. Testing of coil ignition system parts

-

4

13.4. Spark plug testing w.r.t colour / physical

-

4

-

4

13.5. Checking of C.D.I system

-

3

13.6. Checking of pulsar coil resistance

-

6

13.7. Checking of ignition coil

-

4

& parts 13.

Ignition System.

condition



8

13.8. Checking of condenser. 14.

Introduction of lubrication system

15

Lubrication system

4

-

15.1. Inspection of oil pump

-

4

15.2. Oil changing procedure

-

5

15.3. Checking & cleaning of oil strainer / fitter

-

1.5

15.4. Oil passages cleaning

-

4

15.5. Introduction of engine oil with grade

-

1.5

15.6. Checking of oil level

-

2

15.7. Inspection of oil seal/replacement.

-

15

16

Cooling system

3

-

17

16.1 Cooling 16.2 Main parts 16.3 Function Transmission & clutch

6

-

18

Clutch mechanism. 18.1. Adjustment of clutch free play

-

5

18.2. Changing of clutch plates

-

7

18.3. Checking of pressure plate.

-

5

18.4. Inspection / checking of spring (free length)

-

5

18.5. Clutch cable/ wire replacement / checking

-

8

19

Transmission. 19.1. Removing of transmission

20

19.2. Inspection of gears/ washers

-

6

19.3. Refitting & reassembling of transmission

-

20

20 O Starting system. 19.4. Kick and spindle replacement.

-

20

4

-

21.1. Checking of brake mechanism

-

5

21.2. Checking of Disc brake

-

5

21.3. Brake shoe replacement

-

10

19.5. Introduction of self starter system 21

Principle of Brake system.

22.

Brake System



9

21.4. Brake adjustment

-

4

21.5. Replacement of rubber pads

-

7

21.6. Replacement of wheel bearing.

-

10

23

Principle and introduction of Suspension System.

7

-

24.

Suspension System (Front / Rear)

-

23.1. Inspection of front fork suspension (shock

10

absorber)

15

23.2. Maintenance / service of front shock absorber

20

23.3. Replacement of handle ball & cap. 25.

26.

Battery

-

24.1. Checking (electrolyte level / gravity)

5

24.2. Charging

10

24.3. Preparation of electrolyte.

10

Charging system 25.1. Inspection of charging system

-

10

27.

Tuning Procedure

-

20

28.

Top Over Hauling Procedure -

25

27.1. Inspection of valve timing gears/ sprocket and their setting 27.2. Inspection of cylinder head and remove all parts

15

27.3. replacement of valve and valve guide

8

29.

Engine overhauling procedure

-

35

30.

Fault finding and their remedies

-

15

60

680

Total



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LIST OF TOOLS / EQUIPMENT (For a Class of 20 Students) (6-Months Course) Name of Trade

Motor Cycle Mechanic

Duration of Course

06 – Months

Sr. No.

Name of Tools / Equipments

Quantity

1.

Tool box (trolley type)

10 Nos.

2.

Steel foot rule 6”

10Nos.

3.

Steel foot rule 12”

10 Nos.

4.

Venire caliper o to 160 mm

10 Nos.

5.

Feeler gauge

10 Nos.

6.

Screw driver flat tips size 3 mm

10 Nos.

7.

Screw drive flat size 7 mm

10 Nos.

8.

Screw drive flat tip size 4 mm No.1

10 Nos.

9.

Screw driver Philips No.2

10 Nos.

10.

Screw drive Phillips No.3

10 Nos.

11.

Screw drive Phillips

10 Nos.

12.

Stubby screw driver flat

10 Nos.

13.

Tubby screw drive Phillips

10 Nos.

14.

File flat 300 mm

10 Nos.

15.

File flat 200 mm

10 Nos.

16.

Round file 200 mm

10 Nos.

17.

Half rounder file 200 mm

10 Nos.

18.

Allen key set 400 mm

10 Nos.

19.

Double open end spanner set 6 to 32 mm

10 Nos.

20.

Off set ring spanner set 6 to 32 mm

10 Nos.

21.

Open and ring spanner (combination) 6 to 22 mm

10 Nos.

22.

Box Spanner Set

10Nos.

23.

Screw wrench adjustable 6”

10Nos.

24.

Screw wrench adjustable 8”

10 Nos.

25.

Ball pin hammer 50 gm

10 Nos.



11

26.

Cross pin hammer 250 gm

10 Nos.

27.

Combination plier 6”

10Nos.

28.

Nose plier 6”

10Nos.

29.

Grip Plier 8”

10 Nos.

30.

Oil can

10 Nos.

31.

Needle file set (set of 12 pieces)

10 Nos.

32.

File cleaning brush

10 Nos.

33.

Flat chisel

10Nos.

34.

Rubber hammer

10 Nos.

35.

Plastic hammer

10 Nos.

36.

Hack saw frame 12”

8 Nos.

37.

Socket Set complete 6 to 32 mm (12 side)

10 Nos.

38.

Socket set complete 6 to 32 mm (6 side)

10 Nos.

39.

Dial indicator gauge range 50 to 150 mm

04 Nos.

40.

Micro meter 0 to 25 mm

04 Nos.

41.


04 Nos.

42.


04 Nos.

43.

Tray G1 sheet 18”*24”

04 Nos.

44.

Oil Gun

05 Nos.

45.

Timing Gun electronic 6 volt & 12 volt

05 Nos.

46.

Spark plug spanner for different motor cycle special Honda 70, 125, & Yamaha 100

8 Nos.

47.

Puller inside

04 Nos.

48.

Puller out side

04 Nos.

49.

Torque wrench different type

04 Nos.

50.

Bench vice (standard size)

8 Nos.

51.

Work bench

8 Nos.

52.

Lift / Ramp for motorcycle.

4 Nos.

53.

Air com pressor

02 Nos.

54.

Spark plug cleaner & tester

02 Nos.

55.

Battery charger 6 to 12 volt

02 Nos.

56.

Air gun duster (pistal type )

04 Nos.

57.

Socket handle spanner (T-Type) 8,9,10,12,14 mm.

04 Nos.

58.

Impact screw driver set (hammering type )

04 Nos.



12

59.

Motor cycle Honda CD-70

02 Nos.

60.

Motor cycle Honda CG-125

02 Nos.

61.

Motor cycle Yamaha YB 100

02 Nos.

62.

Motor cycle Suzuki 80CC

02 Nos.

63.

Engine 2 stroke

03 Nos.

64.

Engine 4 stroke CD-70

05 Nos.

65.

Engine 4 stroke CG 125

04 Nos.

66.

Valve compressor

04 Nos.



13

LIST OF EQUIPMENT / TRAINING MATERIAL FOR 20 TRAINEES Sr. No. 1.

List of Items

Quantity

4 - Stroke Engine (Motor Cycle) i. Honda CD70 ii. Honda CG125 iii. Yamaha 100 CC iv. Suzuki 110 CC

02 Nos. 02 Nos. 02 Nos. 02 Nos.

2.

2 – Stroke Engine

01 Nos.

3. .

Motor Cycle (Complete) (Honda, Yamaha, Suzuki, 4 Stroke)

01 Nos. (each)

4.

Carburetor (Different types)

04 Nos.

5.

Clutch Assembly Complete (Different Types)

04 Nos.

6.

Hydraulic Brake System (Disc Brake)

7.

Shock Absorbers (Rear / Front)

02 Sets

8.

CDI System (unit)

02 Nos.

9.

Battery (12V Motorcycle)

04 Nos.

10.

Ignition Coil 12v

04 Nos.

11.

Timing Chain

02 Nos.

12.

Chain Sprocket Set

02 Nos.

13.

Piston / Piston Ring Set

02 Set

14.

Catalogue / Data Books (Honda CD70, CG125, Yamaha 100 CC, Suzuki 110 CC)

01 No. Each


02 Nos. (Complete System)


14

FURNITURE S.#

Name of Articles

Quantity

1.

Working bench

10 No’s

2.

Wooden stool (for students)

15 No’s

3.

Chair for teacher

02 No’s

4.

White board (3 ½ x 5ft) with stand

01 No.

5.

Steel Almirah (4 x 7 ft)

04 No’s

6.

Instructor table with 3 drawers

01 No.



15

SPECIAL EQUIPMENT 1.

HONDA Motorcycle Company tool display board CD 70 & CG 125. (1 Set)

2.

YAMAHA Motorcycle Company tool display board. (1 Set)

3.

SUZUKI Motorcycle Company tool board. (1 Set)



16

MINIMUM QUALIFICATION OF INSTRUCTOR

?

Diploma of Associate Engineer in Auto &Diesel Technology with two years experience in relevant field (especially in motorcycle repairing). OR

?

Two-years certificate in Auto & Diesel Mechanic (G-II level) alongwith 6-years experience in relevant field.



REFERENCE BOOKS

1. Trainee manual of auto mechanic course developed by PVTC, Lahore. 2. “Auto servicing“ by Allama Iqbal Open University, Islamabad.

3. “Auto Mechanic” by WH Crouse.


17


18

EMPLOYABILITY OF PASS OUTS

The pass outs of this course can find job / employment opportunities in the following areas / sectors:-

1.

Motor cycle repair shops.

2.

Motor cycle sales shops.

3.

Various Motor cycle production units.
