Demonstrate & Excersice-1

Checking Battery Charge Level

STEP 1. Wear safety glasses

STEP 2. Remove vents caps of all the battery cells

Checking electrolyte specific gravity

STEP 1. Once the vents caps are removed squeeze the hydrometer bulb

STEP 2. Insert the tube into cell then slowly release the bulb to allow the

STEP 3. Do not remove the hydrometer from the cell and ensure that float is electrolyte
flow in to hydrometer and float to move up free without touching the side walls.

Readings

STEP 1. Take the reading of electrolyte specific gravity on the float.

STEP 2. Repeat this for remaining cells Battery Charging

Process Initial setup

STEP 1. Remove the battery from the vehicle before charging.

STEP 2. Clean dirt and corrosion from the terminals

STEP 3. Check electrolyte level and add distilled water if needed

STEP 4. Charge the batteries in a ventilated area

Safety Precautions

STEP 1. Wear safety glasses, shoes, rubber gloves and apron

STEP 2. Do not smoke and keep sparks or flames away from the battery

STEP 3. Do not mix batteries

Charging

STEP 1. Remove the vent caps, connect the batteries and switch ON the charger

STEP 2. Preferably charge the battery at slow rate STEP

3. Intermittently check specific gravity during charging, stop charging when specific
gravity reaches full charge state

STEP 4. Intermittently check battery temperature by touching the battery during

charging.

STEP 5. If battery becomes hot, stop charging and let it cool before resuming charging.

Demonstrate & Exercise-2

Engine dismantling

STEP 1. Drain the oil

STEP 2. Remove Subassemblies like generator, starter motor, oil filter and engine
flywheel.

STEP 3. Remove Cylinder head cover, rocker-shaft assembly and push rods.

STEP 4. Remove manifolds.

STEP 5. Pull off high pressure fuel lines (In diesel engines).

STEP 6. Remove all studs in the cylinder block cylinder head.

STEP 7. Place the engine in upside down position

STEP 8. Remove oil sump

STEP 9. Remove oil strainer and oil pump.

 STEP 10. Remove connecting rod caps and take is out from their place.

STEP 11. Remove pistons and connecting rods from topside of cylinder bore.

Engine assembly

STEP 1. Clean all the mating faces and reusable parts thoroughly and check them for
damage.

STEP 2. Fit the crankshaft

STEP 3. Install the pistons and lubricate

STEP 4. Fit the bearing caps

STEP 5. Install the crankshaft pilot bearing

STEP 6. Install the rear oil seal housing

STEP 7. Align the oil seal housing

STEP 8. Fit the crankshaft rear oil seal

STEP 9. Fit the crankshaft oil seal housing

STEP 10. Fit the oil baffle

STEP 11. Fit the oil strainer

STEP 12. Apply sealing compound to the cylinder block on the flywheel side.

STEP 13. Fit the sump using a new gasket

STEP 14. Align the sump

STEP 15. Fit the flywheel

STEP 16. Centre the clutch disc on the pressure plate

STEP 17. Fit the clutch assembly

STEP 18. Clean and reassemble the oil pump

STEP 19. Fit the oil pump using a new gasket

STEP 20. Fit the cylinder head

STEP 21. Tighten the cylinder head bolts

STEP 22. Tighten the auxiliary cylinder head bolts

STEP 23. Install the camshafts

STEP 24. Fit the timing chain

STEP 25. Install the oil pump assembly

STEP 26. Fit the lower timing chain cover

STEP 27. Fit the crankshaft vibration damper

STEP 28. Fit the cylinder head cover with a new gasket

STEP 29. Attach the engine mounting bracket

STEP 30. Fit the oil filter

STEP 31. Fit the alternator and bracket

STEP 32. Fit the inlet manifold bracket

STEP 33. Fit the EGR system (if available)

STEP 34. Install the brackets for the air conditioning compressor and the exhaust (If
applicable)

STEP 35. Detach the engine from the assembly stand

STEP 36. Attach the engine mounting bracket with the engine mounting.

STEP 37. Finally fill up with engine oil

 Demonstrate & Execrise-3

Compression test

STEP 1. Switch on ignition key & start the engine.

STEP 2. Ensure the engine temperature should be 60º C & then switch off the ignition
key.

STEP 3. Disconnect the left hand side ‘spark plug cap’ & remove the spark plug. Also
disconnect spark plug cap from right hand side spark plug. Confirm ignition switch is in
‘OFF’ condition.

STEP 4. Thread in adaptor and fix compression pressure gauge in cylinder head plug hole
for left hand side spark plug.

STEP 5. Give full throttle & apply 5 to 6 sharp kicks.

STEP 6. In case of vehicle is without kick, press self start button 5 to 6 times.

STEP 7. Note the engine compression pressure reading on the pressure gauge.

STEP 8. To compare the compression pressure refer vehicle specification chart.

STEP 9. If engine compression pressure reading in dry compression test is less than
specified, carry-out ‘wet compression test’.

STEP 10. In wet compression test, pour few drops of engine oil through plug hole in
cylinder head.

STEP 11. Give full throttle & apply 5 to 6 sharp kicks. In case of vehicle without kick,
press self start button 5 to 6 times.

STEP 12. Note the engine compression pressure reading on the pressure gauge.

STEP 13. If wet compression pressure reading is considerably greater than dry
compression pressure reading, this means the problem area is block piston.
 STEP 14. If wet compression pressure reading is same as dry compression pressure
reading, this means the problem area is cylinder head.

Demonstrate & Excerscise-4

Valve Clearance

STEP 1. Do Valve Clearance setting at engine cold condition.

STEP 2. Open the generator cover & cylinder head cover. a. Ensure piston is at TDC
position by aligning marking of rotor & crankcase. b. Ensure cam sprocket horizontal line
marks should align with cylinder head surface

STEP 3. Caution: Timing chain sprocket should be rotated in clockwise direction only.
STEP 4. With help of filler gauge check valve clearance inlet / exhaust & adjust as per
recommended specification

STEP 5. Filler gauge should have a mild resistance when being slide out after setting the
valve clearance.

STEP 6. With help of special tool ensure proper locking of check nut of rocker arm
screw.

STEP 7. Complete two rotation of engine & recheck the valve clearance.

STEP 8. Refit generator cover & cylinder head cover.

Valve timing

STEP 1. Rotate the crank shaft.

STEP 2. Bring the piston no one to TDC.

STEP 3. Rotate the cam shaft with the sprocket.

STEP 4. Install the chain on the crank shaft sprocket.

STEP 5. Fix the camshaft sprocket, along with the chain on the camshaft, align the bolt
holes or dowel.

STEP 6. Check and align the timing marks on the sprocket.

STEP 7. Recheck the alignment of the timing marks by rotation.

STEP 8. Carry out a valve timing check, if necessary

 Demonstrate & Excersice-5

Air Filter Element Cleaning (Foam)

STEP 1. Dip the foam in kerosene available in the first pot of the ‘Air Filter Stand’. Then
squeeze the foam to remove excess kerosene/Diesel & dirt.

STEP 2. Further clean the foam by dipping it into clean kerosene/Diesel available in the
second pot of the ‘Air Filter Stand’. Again squeeze it. Apply low pressure (less than 2
bar) air on foam to dry it.

STEP 3. Never use petrol for cleaning air filter foam.

STEP 4. Dip the foam completely in the third pot of the air filter stand that contains
engine oil. Allow the oil to soak into the foam and then take out the foam.

STEP 5. Squeeze foam completely to take out excess oil.

STEP 6. Use dry lint free cotton cloth to remove excess oil. Do not twist the air filter
foam as this may lead to tear or bulge.

STEP 7. Replace Diesel / Kerosene / Engine oil of air filter stand after 25 filter cleaning.
Air Filter Element Cleaning (Paper Type)

STEP 8. Use filtered compressed air of pressure less than 2 bar. Position air gun straight
at 90 Deg. angle & 50 mm away from paper filter. Move the air gun along the fold line.

STEP 9. Positions air gun at 45 Deg. angle & 50 mm away from paper filter. Slightly
twist the paper filter. Move the air gun along the fold line.

STEP 10. Keep air gun straight at 90 Deg. angle & 50 mm away from paper filter. Blow
off remaining dust by moving air gun along the fold line. Engine Air Breather Tube
Replacement

STEP 11. Press the clamp & disconnect the ‘engine breather tube’ from crankcase & ‘Air
Filter Box’.
 STEP 12. Check the breather tube for any cracks & damage, if found replace. Refit the
breather tube & its clamps properly

Demonstrate & Excersice-6

Fuel Cock Sediment Bowl Cleaning

STEP 1. Put the petrol cock knob to ‘off‘ position.

STEP 2. Remove the petrol cock sediment bowl by using a ring spanner.

STEP 3. Pour out the petrol to remove sludge and sediment from “Petrol cock sediment
bowl”.

STEP 4. Remove strainer from petrol cock body.

STEP 5. Clean the bowl and the strainer with the help of petrol and nylon brush.

STEP 6. Refit the strainer and the bowl.

STEP 7. Put fuel cock knob in ON / Res. position & confirm no leakage.

Fuel Cock-paper Filter Element Replacement

STEP 1. Put fuel cock knob in off position

STEP 2. Remove fuel cock sediment bowl by open end spanner.

STEP 3. Take out fuel cock sediment bowl.

STEP 4. Pull out paper filter element with seal from fuel cock body

STEP 5. Clean sediment bowl thoroughly with low pressure compressed air.

STEP 6. Replace paper filter element with seal at every 15000 kms.

STEP 7. To avoid cross thread fitment of sediment bowl do pre fitment of sediment bowl
by hand & there after tightening by ring spanner.
 STEP 8. Put fuel cock knob in ON / Res. position & confirm no fuel leakage Carburetor
Cleaning Process

Demonstrate & Excersice-7

Carburetor Float Chamber Cleaning

STEP 1. Loosen drain screw and flush out petrol from the “Carburetor bowl”.

STEP 2. Then re-tighten the drain screw.

STEP 3. Loosen clamps, of rubber duct.

STEP 4. Remove intake manifold bolts and take out carburetor along with manifold and
duct.

STEP 5. Remove Philips screws securing the “Carburetor bowl” to the Carburetor body.

STEP 6. Take out “Carburetor bowl”

STEP 7. Pour out sludge and sediment from “Carburetor bowl”

STEP 8. Clean the “Carburetor bowl” by petrol & soft nylon brush.

STEP 9. Refit the “Carburetor bowl”

STEP 10. Tighten the screws of “Carburetor bowl”

STEP 11. Refit carburetor on vehicle & confirm no fuel leakage.

Auto Choke Checking

STEP 1. Check for auto choke click sound when ignition switch is switched ON. If click
sound. is not heard then - remove Choke Unit from Carburetor assembly.

STEP 2. Switch ‘ON’ Ignition Key. Solenoid operated choke plunger must get lifted for
a second & then again plunger must fall down in engine OFF condition. Connect solenoid
operated choke connection to external supply of 12volt DC & check / confirm the
working of choke
 STEP 3. Set multimeter on 200 ohm range. Connect multimeter probes to auto choke
coupler.

STEP 4. Note the resistance value & compare with specs.

Demonstrate & Excersice-8

Silencer Tail Pipe Cleaning Process

STEP 1. Park the vehicle on center stand in neutral gear position & with engine in ‘off’
condition.

STEP 2. Insert ‘Wire Bristle Brush’ into the tail pipe of silencer assembly and scrub
inside walls of the tail pipe. While scrubbing, ensure that pressure is applied to the tail
pipe inner surface so that holes on the tail pipe can get cleared off from carbon black /
soot.

STEP 3. Start the engine and give throttle to flush out all the soot that has been scrubbed
off the surface. The scrubbing and flushing activity is to be carried out till no more soot is
seen coming out of the tail pipe after starting the engine.

STEP 4. Switch Off the engine, direct the compressed air inside the tail pipe so that holes
on the tail pipe get cleared. Ensure that the compressed air hose nose is directed towards
the wall / holes on wall around till the end of tail pipe.

Demonstrate & Excersice-9

Inspection of suspension system

STEP 1. Place the vehicle on a hoist or jack.

STEP 2. Lift the vehicle with jack stand to a certain height and bloc the wheel so it
should not move forward.

STEP 3. Slowly rotate the front tyre, looking at the tread wear if so toe setting, or camber
setting is to be done.
 STEP 4. Place your hands on the tyre at the 3-and-9 o’clock positions of the tyre and try
to shake it firmly back and front if excessive ply use tie rod ends could be loose/worn out.

STEP 5. Place the hand on the tyre at 6-and 12 o’clock positions of the tyre and shake it
back and front if excessive ply use tie rod ends could be loose/worn out

STEP 6. Any joint/pivot point that has ply or a clicking sound needs to be fully inspected
and replaced in each suspension system.

STEP 7. Lubricate all the replaced components by grease to avoid wear and tear.

Servicing of suspension system

STEP 1. Park the vehicle on the level ground and loose the nuts on both sides of the front
& back end places and then place the vehicle with ramps or jack stands.

STEP 2. Remove shock bolts from shock tower by using ratchet and socket.

STEP 3. Disconnect the shock absorber from the suspension by removing bolt and nut
using socket set or a nut splitter.

STEP 4. By using locking pliers remove the shock absorber from the bottom and top
bolts mounted on studs with retaining brackets.

Demonstrate & Excersice-10

Dismantling & Assembling of Wheels Removing Hub cap

STEP 1. Use a flat screwdriver or the flat end of the lug wrench to remove the hubcap.

STEP 2. Place the hubcap in trunk so it doesn’t get scratched up Loosen wheel nuts

STEP 3. Fit one end of the lug-nut wrench on to the lug nut

STEP 4. Turn it counter clockwise.

STEP 5 Loosen each nut.

STEP 6. Continue until you’ve loosened each lug nut. Jack the vehicle
 STEP 6. Place the jack in place and raise the vehicle slowly. Make sure the vehicle
doesn’t try to roll away as the wheel comes off the ground. Jack the vehicle up until it is
high enough to remove the old wheel and put the new wheel on.

STEP 7. The new wheel may be bigger in diameter than the old flat wheel.

STEP 8. You need enough room for the new Tyre to fit.

Repairing Punctured Tyre

STEP 1. Check the rubber for pierced and examine whether the cut or puncture has
happened. If you failed to check the puncture on tyre, check the tube such that tube itself
has developed wear and tear/cuts.

STEP 2. Jack up the vehicle using jacks and ensure the vehicle is lifted in a balanced
position STEP

3. Using the lug-nut spanner, unscrew the bolts and remove the wheel

STEP 4. Separate the tyre from the rim. Use the tyre iron to remove the tyre from the rim.
Slot the tool at the intersection of the rim and the rubber and gently push the lever and
allow the tyre to Demonstrate gradually side out along the circumference of the rim.

STEP 5. Unbolt the valve and separate the tube from the tyre. Inflate the tube and
immerse the tube in water.

STEP 6. The air bubbles in the water indicate the punctured area in the tube.

STEP 7. Rub the punctured area with the file to ensure that the adhesive allows the
rubber patch to stick properly.

STEP 8. Use the adhesive to stick the rubber patch over the punctured area.
STEP 9. Check if the puncture is sealed by submerging in water. Put the tube back into
the tyre. Push the air valve through the hole of the rim and gently push the tube into the
tyre. Put the wheel back and tighten the nut.

Demonstrate & Excersice-11

Repairing mechanical brakes

STEP 1. Remove/unthread the wheel nuts with spanner and separate the wheel from
brake drum.

STEP 2. Straighten and pull out the spilt pin, fitted in castle nut, using combination plier.

STEP 3. Lock the axle shaft by putting the vehicle and open the castle nut using socket
and handle.

STEP 4. Hammer the axle shaft lightly by using brass drift, this may contract brake drum
loose and remove brake drum.

STEP 5. Remove brake shoe lock, mount on anchor pin, with the help of nose plier.

STEP 6. Serrate the brake shoes from brake lever cam and the steady post.

STEP 7. Clean the brake shoes and the brakes drum with the help of emery paper.

STEP 8. Fit both the shoes on the cam and anchor pin and lock them.

STEP 9. Fit the brake drum over the axle shaft and tighten the castle nut with the help of
socket and handle.

STEP 10. Tighten the brake shoe adjusting nut with the help of spanner, this makes the
shoes to expand and grip the drum firmly.

STEP 11. Loosen the adjusting nut by a little amount and turn the wheel, it must roll free.
Do the shoe adjustment this way

STEP 12. Tighten the main nut locked it properly.

STEP 13. Fit the wheel over brake drum and tighten wheel nuts.

STEP 14. Take a road test of the vehicle.

Tips during repairing mechanical brake

1. Shoe’s lock must be placed properly.

 2. Shoe’s adjustment should be done properly.

3. If there is any lubricant etc. on brake lining, it must be cleaned by washing the brake
shoe with petrol and further cleaned using emery paper.

4. Brake cable should be checked for its tension and fitted straight.

5. Free play should always be kept in brake pedal.

6. Shoe return spring should be checked for its tension and fitted straight.

7. Replace the brake drum, if it is worn out beyond specifications never get the sleeve
fitted in it.

8. Spilt pin should be placed in castle nut and bended.

9. Spring washer should be placed below each wheel nut and these nuts must be tightened
in the right manner and with the right torque. Over- tightening may damage the stud/-
threads.

10. Brake’s testing should be done at nominal speed of 20 – 35 km/hr only.

Maintenance of brake liner

STEP 1. Jack up the vehicle using floor jack and remove the wheel

STEP 2. Release the parking brake

STEP 3. Detach the drum

STEP 4. Remove the screw attaching drum from bearing hub

STEP 5. Clean the back plate with a stiff brush to remove the accumulated brake dust

STEP 6. Remove the grease on shoes using waste or emery paper

STEP 7. Inspect brake shoes for wear either by checking thickness of shoe is lining with
a base metal or to check thickness of brake lining. Replace the brake shoes if thickness of
lining is above service limit.
Maintenance of brake pads

STEP 1. Jack up the vehicle using floor jack and remove the wheel

STEP 2. Remove the brake caliper by removing the bolt

STEP 3. Remove the brake pads and clean using emery paper

STEP 4. Check the brake pads thickness if it exceeds wear limit then replace it with new
brake pads

STEP 5. Apply grease to caliper bolts before refitting

Servicing of the disc Brakes

STEP 1. Keep the vehicle on hard surface

STEP 2. Loosen the wheel nuts STEP

3. Raise the front portion of a car support the chassis with stand.

STEP 4. Remove the wheel nuts and remove the wheel

STEP 5. Loosen the castle nut and remove hub from splined shaft.

STEP 6. Unscrew the bleeder valve and drain the brake fluid from fluid line

STEP 7. Now loosen the bolts of caliper holder from caliper assembly and remove the
friction pads and dust caps

STEP 8. Slowly remove the scaling ring from assembly

STEP 9. Unload the caliper assembly

STEP 10. Remove the piston, dust cover, return spring and keep it aside

STEP 11. Thoroughly clean all components and inspect for wear

STEP 12. Inspect the disc surface for scratches

 STEP 13. Measure for the defection disc and if more, replace the disc or it will create
shaking steering or brake judder

STEP 14. Inspect the thickness of disc (std-11mm, limit 9.5mm)

STEP 15. Inspect the piston for wear or replace the kit

STEP 16. Assembly the disc on the hub

STEP 17. Fix the piston in caliper assembly with rubber seals

STEP 18. Also, replace the brake pads and assemble the wheel Add the brake fluid in
reserve tank

STEP 19. Carry out brake bleeding operation after adjusting friction pads

STEP 20. Test the working of brakes.

Brake Fluid Level top Up

STEP 1. Wash the vehicle

STEP 2. Check the brake fluid level in the master cylinder through inspection window

STEP 3. If the brake fluid level is below the minimum mark, remove 2 nos. Phillips head
screws and remove master cylinder reservoir cover.

STEP 4. Take out plastic cover and diaphragm.

STEP 5. Check rubber diaphragm for damages

STEP 6. Top up the oil level by pouring the DOT 3 / DOT 4 brake fluid in the master
cylinder reservoir till the level is above the minimum mark

STEP 7. Refit the diaphragm, plastic cover and master cylinder cover. Tighten the screw
securely.

STEP 8. Check the condition & routing of the brake hose pipe.

Brake fluid replacement

 STEP 1. Clean the surface area of master cylinder

STEP 2. Drain the brake fluid from caliper air bleeder bolt.

STEP 3. Tight the air bleeder bolt on caliper assembly.

STEP 4. Remove reservoir cover by removing 2 nos. phillips head screws.

STEP 5. Remove PVC Cap & rubber diaphragm.

STEP 6. Fill the master cylinder reservoir by using or DOT-3/DOT4 brake fluid.

STEP 7. Conduct the brake bleeding procedure & maintain the brake fluid level above
MIN. mark.

STEP 8. Fit the master cylinder cover.

STEP 9. Press the front brake lever and check the operation of disc brake.

STEP 10. Perform air bleeding of disc brake system if the brake operation is spongy.

STEP 11. For drum brake vehicles, check and adjust front brake lever free play. It should
be 4 to 5 millimeters for all motorcycles.

STEP 12. Ensure front wheel is rotating freely.

Brake bleeding process

STEP 1. Fill the master cylinder’s reservoir with brake fluid up to top as level marked on
it.

STEP 2. Ask the companion to sit on driver’s seat and create fluid pressure by pressing
and releasing the brake pedal several times. You will feel that the pedal became hard.

STEP 3. Asked the companion to keep up foot pressure on brake pedal. Insert one end of
the pipe’s over the bleeding nipple and let the other end in a glass bottle / jar.
 STEP 4. Release the fluid pressure by opening the bleeding nipple and farther most wheel
cylinder from master cylinder. There will be bubbles with brake fluid coming out in the
bottle/jar.

STEP 5. Tighten the nipple

STEP 6. Again ask your companion to repeat the procedure and release the pressure
through the same nipple. This time there should be no bubbles and only the brake fluid
should be coming out of it.

STEP 7. Check the fluid level, it will be bit down, then top-up the level.

STEP 8. Apply the same steps to other wheel cylinders also, turn by turn.

STEP 9. Checked the free play of brake pedal.

STEP 10. Adjust the free play by unthreading the push rod.

STEP 11. Test the vehicle

Demonstrate & Excersice-12

Servicing Drive Chain

STEP 1. Put vehicle on center stand.

STEP 2. Remove rubber cap from chain inspection window.

STEP 3. Rotate rear wheel to find out the position at which chain is getting tight.

STEP 4. Measure chain slackness by steel rule by pulling up and pushing down the chain
to find out maximum slackness.

STEP 5. To set chain slackness, first loosen the rear brake rod nut by using a flat or ring
spanner.

STEP 6. Remove the lock pin by using combination plier and loosen the tie rod nut by
using ring spanner.
 STEP 7. Loosen the bearing carrier nut by using ring spanner.

STEP 8. Check & confirm that the marks on left hand & right hand chain adjusters are
equally placed.

STEP 9. To keep the chain & rear wheel properly aligned, the arrow mark on the left and
right adjusters must be equidistant from their respective rear edge of ‘swing arm notch’.

STEP 10. Hold the left chain adjuster nut in flat spanner and tighten the lock nut.

STEP 11. Repeat the same procedure for right chain adjuster lock nut.

STEP 12. Rotate the rear wheel and apply rear brake so that the brake panel takes its own
position.

STEP 13. Tighten the bearing carrier nut to the specified torque.

STEP 14. Tighten the rear axle nut to the specified torque.

STEP 15. Tighten tie rod bolt to specified torque & refit the lock pin.

STEP 16. Adjust rear brake pedal free play. Recommended rear brake pedal free play is
25 to 30 mm.

STEP 17. Check and ensure that rear wheel is rotating freely

Demonstrate & Excersice-13

Two and Three Wheeler Maintenance

Daily Inspection (DI):

Visual inspection to all tyres to check the pressure and also observing the sound of tyre while
hitting it with stone piece.

 Check coolant level in radiator (If applicable).

 Check intactness of fan belts (if applicable).
 Check engine oil level.
 Check the wind screen, rear view mirror and rear window glass for their cleanliness.
Maintenance Checkup:

1. Oil level topping

2. Intactness of Belt

3. Cleanliness of battery for and electrolyte level Elaborate

4. Functioning of brakes

5. Level of coolant in the coolant reservoir

6. Cooling system hoses intactness

7. Tyre pressure

Tips during maintenance checkup

 Do not put sharp objects, such as screw drivers, in your pocket. You could cut
yourself or get stabbed, you could damage the seat.
 Make sure that technician should use proper shoes and their dress should be as per
job requirement.
 If oil, grease, or any liquid spill on the floor, cleans it up so that no one will slip
and fall.
 When using a grinding wheel wearing eye protection is must or welding
equipment or working with chemicals-such as solvents.
 While using jack, place it properly to avoid slip.
 Never run an engine in a closed garage that does not have proper ventilation
system.
 The exhaust gases contain carbon monoxide. Carbon monoxide is a colorless,
odorless, tasteless poisonous gas that can kill you.

Demonstrate & Excersice-14

Oil pressure test

STEP 1. Read the service manual of the engine that the gauge will be testing.
 STEP 2. During engine testing process vehicle should be parked on a level surface, it
should be in neutral gear with front brake applied and chocked wheels.

STEP 3. The oil pressure / temperature sensor is usually located on or near the oil pan at
the lower part of the engine. Clean the area thoroughly before proceeding.

STEP 4. Only connect the gauge when the engine is off and cool

STEP 5. Place a pan below the sensor to store oil, remove the sensor, and thread the
gauge into the opening

STEP 6. Attach the appropriate fitting to the gauge

STEP 7. Check the oil level and fill as needed

STEP 8. Start the vehicle and allow it to come to normal running temperature

STEP 9. Compare the reading on the gauge to the numbers on the chart. If the actual
reading is lower or higher than the numbers indicated on the chart have the engine needs
to be serviced.

STEP 10. Turn the vehicle off and allow it to cool before removing the gauge

STEP 11. Replace the oil pressure/temperature sensor, refill oil as necessary

STEP 12. Clean, and then store the tool properly

Demonstrate & Excersice-15

Dismantling the wheel baring

STEP 1. Secure the vehicle on a flat rigid floor.

STEP 2. Loosen the break by loosening the brake lock nut STEP

3. Remove the wheel using DE spanner

STEP 4. Remove the break shoe, remove the wheel and pull out the bearing shield.

STEP 5. Remove the ball bearing using suitable plier/puller.

 STEP 6. Clean the bearing thoroughly with kerosene and allow it to dry (care should be
taken not to dry the bearing with s to compressed air as the air may contain moisture
which is harmful to the bearing.

STEP 7. Test the bearing manually by rolling and check for any noise, pay.

STEP 8. Lubricate the bearing with recommended grease and once again check for any
noise or distortion if noise still persists it indicates the balls have worn out and bearing is
to replaced

Demonstrate & Excersice-16

Vehicle Washing and Cleaning

Interior and Exterior cleaning

STEP 1. Cover tail end of silencer with PVC cap to avoid water entry in silencer

STEP 2. Set water washer pressure for vehicle washing is 25 bar max. & set the nozzle in
spray mode.

STEP 3. Clean the exterior surface of engine metal parts by diesel or kerosene with soft
nylon brush

STEP 4. Dismantle the small chain cover & clean the area between magneto cover &
engine sprocket by using nylon brush and kerosene or diesel

STEP 5. Wash the vehicle by keeping nozzle 2 meters away from parts

STEP 6. Adjust nozzle to jet mode & wash under the front & rear mudguard to remove
the mud & dirt.

STEP 7. Clean painted parts by gently rubbing their surface with solution of mild car
shampoo / liquid solution.

STEP 8. Rub the front & rear tyres by nylon brush to remove dirt & mud.
 STEP 9. Water wash the vehicle with the nozzle in spray mode & clean all soap &
shampoo foam.

STEP 10. Dry the vehicle by using low pressure (2bar) compressed air.

STEP 11. Vehicle should be wiped off by cotton cloth immediately after washing.

STEP 12. To avoid water entry & paper filter, do not apply water on area beneath seat.

Demonstrate & Excersice-17

Replace worn out gear / speedometer cable

STEP 1. If the speedometer moves to a few distance then it is alright

STEP 2. Rotate the front wheel in the forward direction

STEP 3. If the speedometer in not moving then check cable

STEP 4. The cable might be loose. Tighten then at both ends, near the speedometer and
near speedometer.

STEP 5. If the worm gear is worn-out the speedometer oscillates.

STEP 6. Replace gear arrangement

STEP 7. Lubricate the gears and the cable.

Demonstrate & Excersice-18

Maintenance Check-up

STEP 1. Topping of oil level

STEP 2. Proper tension of Belt STEP

3. Battery for cleanliness and level of electrolyte.

STEP 4. Brakes

STEP 5. Toping up of Coolant if required in the coolant reservoir STEP

 6. Check the Serviceability of cooling system Hoses STEP

7. Proper Tyre inflation pressure

STEP 8. Air-conditioning (if applicable) Service at work shop Check/Top up all

vehicles’ oil levels: Service mechanic with the help of measuring stick check the
engine oil, coolant, brake oil, and water. During routine check-up, oil, water,
coolants are topped up otherwise it is changed.

Demonstrate & Excersice-19

Removing windscreen wiper motor

STEP 1. Lift out the motor and linkage together.

STEP 2. Disconnect the wiper arms

STEP 3. Unplug the electrical connections, and then remove the bolts holding the motor
to the bulkhead

STEP 4. Before removing a pushrod system, mark the angles of the rods to aid refitting.

Refitting wiper motor

STEP 1. When reassembling a pushrod linkage, use the guide marks you made to position
rods at the correct angles.

STEP 2. Once the motor is back in place, test the wipers with the blades lifted off the
screen.

STEP 3. Wet the screen with the washer and test the blades in different wiping position.

STEP 4. Take the wiper arms off from their spindles and realign them. Some motors have
an adjuster nut for adjusting the parking position