motor.cycle .mechanic

GOVERNMENT OF THE PUNJAB

TECHNICAL EDUCATION & VOCATIONAL TRAINING AUTHORITY

CURRICULUM FOR

MOTOR CYCLE MECHANIC

(6 Months Course)

CURRICULUM SECTION ACADEMICS DEPARTMENT

96-H, GULBERG-II, LAHORE Ph # 042-9263055-9, 9263064

[email protected], [email protected]

CURRICULUM FOR

Motor Cycle Mechanic (6-Months Course)

Developed by Curr iculum Sect ion, Academics Department TEVTA.

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 90% Theory 10%

Medium of Instruction Urdu / English



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).



3

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.



4

CCUURRRRIICCUULLUUMM DDEELLIIVVEERRYY SSTTRRUUCCTTUURREE

Curriculum Delivery Revision Co-curricula Activities Final Test Total

1-20 21 22-25

26

W E E K

20 1 4 1

26



5

SCHEME OF STUDIES

Motor Cycle Mechanic (6 Months Course)

Sr. No. Main Topics

Theory Hours

Practical Hours

Total Hours

1. Auto work shop safety precautions/ safe riding - 15 15

2. Introduction of work shop tools & uses - 70 70 3. History of motor cycle( 2 & 4 stroke) 5 - 5 4. Internal and external; combustion engine. 5 - 5

5. Introduction of workshop equipment / special tools and their uses. - 59 59

6. Introduction of main motor cycle parts with the help of their catalogue consolation of service manual / Data books

- 70 70

7. Working of 4 stroke motor cycle engine 6 - 6

8. comparison of 2 stroke and 4 stroke motor cycle engines 6 - 6

9. Fuel system and venturi effect 8 - 8 10. Fuel system. - 49 49 11. Replacement of chain sprocket set. - 15 15 12. Principle of ignition system 6 - 6 13. Ignition System. - 34 34 14. Introduction of lubrication system 4 - 4 15. Lubrication system - 33 33 16. Cooling system 3 - 3 17. transmission & clutch 6 - 6 18. Clutch mechanism - 30 30 19. Introduction / working of transmission - 46 46 20. Starting system. - 20 20 21. Principle & introduction of brake system 4 - 4 22. Brake system - 41 41

23. Principle & introduction or suspension system 7 - 7

24. Suspension System (front / rear) - 45 45 25. Battery - 25 25 26. Charging System - 10 10 27. Tuning procedure - 20 20 28. Top over hauling procedure - 48 48 29. Engine overhauling procedure - 35 35 30. Fault finding & their remedies - 15 15 31. Functional English 20 20 40 32. Work Ethics - 20 20

TOTAL 80 720 800



6

DETAIL OF COURSE CONTENTS

Motor Cycle Mechanic (6 Months Course)

Sr. No Detail of Topics Theory Practical

1. Auto workshop safety precautions / safe riding - 15

2. Introduction of workshop tools & their uses.

2.1 Fitting tools & their uses

2.2 Measuring tools & measuring exercise

2.3 Marking tools & their uses

2.4 Cutting tools & cutting exercise

2.5 Filing exercise

2.6 Drilling exercise

2.7 Threading exercise

2.8 Extraction exercise

-

-

-

-

-

-

-

-

7

15

4

10

16

10

5

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

5.2. Use of timing tester.

5.3. Use of timing Gun/buzzer

5.4. Use of digital tachometer

5.5. Use of dial indicator tester

5.6. Use of multi tester

5.7. Use of tachometer

5.8. Use of timing gear removing puller and refitting

tools

5.9. Use of magnet base plate

5.10. Use of valve compressor etc.

-

-

-

-

-

-

-

-

-

-

6

6

6

6

6

4

6

5

6

8

6. Motor cycle parts

6.1. Catalogue study / data books

6.2. Body parts removal / refitting

10

30



7

6.3. Engine parts & their uses. -

-

-

30

7. Working of 4 Stroke Motor cycle engine

7.1. Working of 4-stroke motorcycle engine.

7.2. Working of two stroke engine

3

3

-

-

8. Comparison of 2-stroke and 4-stroke engine 6 -

9. Fuel system & venturi effect 8 -

10. Fuel System

10.1. Intrduction

10.2. Service of fuel filter.

10.3. Carburetor purpose and type / service

10.4. Fuel level adjustment in carburetor

10.5. Setting of air fuel ratio w.r.t speed

10.5.1. Manually

10.5.2. With exhaust gas analyzer

10.6. Air, fuel mixture adjustment

10.7. Needle adjustment (selection of needle groove)

10.8. Changing / replacement of needle / jet

10.9. Throttle fitting

10.10. Measurement of jet size.

-

-

-

-

-

-

-

-

-

2

10

8

7

3

3

8

2

6

11. Replacement of chain sprockets set - 15

12. Introduction & working principle of ignition system

& parts

6 -

13. Ignition System.

13.1. C.B point adjustment

13.2. Checking of magnet ignition system

13.3. Testing of coil ignition system parts

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

condition

13.5. Checking of C.D.I system

13.6. Checking of pulsar coil resistance

13.7. Checking of ignition coil

-

-

-

-

-

-

-

-

6

3

4

4

4

3

6

4



8

13.8. Checking of condenser.

14. Introduction of lubrication system 4 -

15 Lubrication system

15.1. Inspection of oil pump

15.2. Oil changing procedure

15.3. Checking & cleaning of oil strainer / fitter

15.4. Oil passages cleaning

15.5. Introduction of engine oil with grade

15.6. Checking of oil level

15.7. Inspection of oil seal/replacement.

-

-

-

-

-

-

-

4

5

1.5

4

1.5

2

15

16 Cooling system

16.1 Cooling 16.2 Main parts 16.3 Function

3 -

17 Transmission & clutch 6 -

18 Clutch mechanism.

18.1. Adjustment of clutch free play

18.2. Changing of clutch plates

18.3. Checking of pressure plate.

18.4. Inspection / checking of spring (free length)

18.5. Clutch cable/ wire replacement / checking

-

-

-

-

-

5

7

5

5

8

19 Transmission.

19.1. Removing of transmission

19.2. Inspection of gears/ washers

19.3. Refitting & reassembling of transmission

-

-

-

20

6

20

20 O Starting system.

19.4. Kick and spindle replacement.

19.5. Introduction of self starter system

-

20

21 Principle of Brake system. 4 -

22. Brake System

21.1. Checking of brake mechanism

21.2. Checking of Disc brake

21.3. Brake shoe replacement

-

-

-

5

5

10



9

21.4. Brake adjustment

21.5. Replacement of rubber pads

21.6. Replacement of wheel bearing.

-

-

-

4

7

10

23 Principle and introduction of Suspension System. 7 -

24. Suspension System (Front / Rear)

23.1. Inspection of front fork suspension (shock

absorber)

23.2. Maintenance / service of front shock absorber

23.3. Replacement of handle ball & cap.

-

10

15

20

25. Battery

24.1. Checking (electrolyte level / gravity)

24.2. Charging

24.3. Preparation of electrolyte.

-

5

10

10

26. Charging system

25.1. Inspection of charging system

-

10

27. Tuning Procedure - 20

28. Top Over Hauling Procedure

27.1. Inspection of valve timing gears/ sprocket and

their setting

27.2. Inspection of cylinder head and remove all parts

27.3. replacement of valve and valve guide

-

25

15

8

29. Engine overhauling procedure - 35

30. Fault finding and their remedies - 15

Total 60 680



10

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.



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. List of Items Quantity

1. 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) 02 Nos. (Complete System)

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



14

FURNITURE

S.# Name of Articles Quantity

1. Working bench 10 Nos

2. Wooden stool (for students) 15 Nos

3. Chair for teacher 02 Nos

4. White board (3 x 5ft) with stand 01 No.

5. Steel Almirah (4 x 7 ft) 04 Nos

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.



17

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.



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.

motor.cycle .mechanic

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