GOVERNMENT OF THE PUNJAB

TECHNICAL EDUCATION & VOCATIONAL

TRAINING AUTHORITY

CURRICULUMFOR
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]
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 90%
Theory 10%
Medium of Instruction Urdu / English

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 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).

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 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.

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 4

CURRICULUM DELIV ERY STRUCTURE

Co-curricula
Curriculum Delivery Revision Final Test Total
Activities

W 1-20 21 22-25 26
E
E
26
K

20 1 4 1

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 5

SCHEME OF STUDIES

Motor Cycle Mechanic

(6 Months Course)
Sr. Theory Practical Total
Main Topics
No. Hours Hours Hours
Auto work shop safety precautions/ safe 15
1. - 15
riding
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
Introduction of workshop equipment / 59
5. - 59
special tools and their uses.
Introduction of main motor cycle parts with 70
6. the help of their catalogue consolation of - 70
service manual / Data books
7. Working of 4 stroke motor cycle engine 6 - 6
comparison of 2 stroke and 4 stroke motor 6
8. 6 -
cycle engines
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
Principle & introduction or suspension 7
23. 7 -
system
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

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 6

DETAIL OF COURSE CONTENTS

Motor Cycle Mechanic
(6 Months Course)

Sr.
Detail of Topics Theory Practical
No
1. Auto workshop safety precautions / safe riding - 15
2. Introduction of workshop tools & their uses.
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
tools
5.9. Use of magnet base plate - 6
5.10. Use of valve compressor etc. - 8
6. Motor cycle parts
6.1. Catalogue study / data books 10
6.2. Body parts removal / refitting 30

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 7

6.3. Engine parts & their uses. - 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
10.5. Setting of air fuel ratio w.r.t speed
10.5.1. Manually
10.5.2. With exhaust gas analyzer - 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
10.10. Measurement of jet size.
11. Replacement of chain sprockets set - 15
12. Introduction & working principle of ignition system 6 -
& parts
13. Ignition System.
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
condition - 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

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 8

13.8. Checking of condenser.

14. Introduction of lubrication system 4 -
15 Lubrication system
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 -
16.1 Cooling
16.2 Main parts
16.3 Function
17 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
19.5. Introduction of self starter system
21 Principle of Brake system. 4 -
22. Brake System
21.1. Checking of brake mechanism - 5
21.2. Checking of Disc brake - 5
21.3. Brake shoe replacement - 10

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 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. Battery -
24.1. Checking (electrolyte level / gravity) 5
24.2. Charging 10
24.3. Preparation of electrolyte. 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 - 25
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
Total 60 680

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 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.
Name of Tools / Equipments Quantity
No.
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.

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 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. Micro meter 25 to 50 mm 04 Nos.
42. Micro meter 50 to 75 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, 8 Nos.
125, & Yamaha 100
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.

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 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.

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 13

LIST OF EQUIPMENT / TRAINING MATERIAL FOR 20 TRAINEES

Sr.
List of Items Quantity
No.
1. 4 - Stroke Engine (Motor Cycle)
i. Honda CD70 02 Nos.
ii. Honda CG125 02 Nos.
iii. Yamaha 100 CC 02 Nos.
iv. Suzuki 110 CC 02 Nos.
2. 2 Stroke Engine 01 Nos.
3. . Motor Cycle (Complete) 01 Nos.
(Honda, Yamaha, Suzuki, 4 Stroke) (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 01 No.
CC, Suzuki 110 CC) Each

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 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.

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 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)

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 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.

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 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.

Developed by Curriculum Section, Academics Department TEVTA.

Motor Cycle Mechanic (6-Months Course) 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.

Developed by Curriculum Section, Academics Department TEVTA.