INTRODUCTION

Type Public company

Industry Automotive

Founded January 19, 1984

Founder Dr. Brijmohan lal Munjal.
Headquarters Gurgaon, India

Key people Dr. Brij Mohan Lal Munjal (Chairman Emeritus) (Dead )
Pawan Munjal (Chairman, MD & CEO)
Products Motorcycles, Scooters
Revenue 241.66 billion (US$3.8 billion) (2013)

Operating income 33.22 billion (US$520 million) (2013)]

Net income 21.18 billion (US$330 million) (2013)

Total assets 53.08 billion (US$820 million) (2013)

Parent The Hero Group

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Introduction:-
The objective of this training is to understanding of automobile two
wheeler parts and major problem appears in two wheelers. Our training gives us
knowledge about Technology involved for servicing of vehicle and skill acquired
for service. Overview of training,
Automobile:-
Automobile is a branch of engineering which deals with designing,
manufacturing and operating automobiles. It is a segment of vehicle engineering
which deals with motorcycles, buses, trucks, etc. It includes mechanical, electrical,
electronic, software and safety elements. Automobile servicing
Automobile service:-
A motor vehicle service is a series of maintenance procedures carried out at
a set time interval or after the vehicle has travelled a certain distance.

So Our Training Is on Automobile service.

Technology involved:-
Technology involved for servicing is mainly the tools which help us to easy
access the parts.
Routine maintenance:-
Routine maintenance can include cleaning and lubing your chain, replacing
brake pads, and changing and fixing a flat tire. For these more simple tasks
following tools as a good starting point: (Wrench set, chain brush, lube and
cleaner, Clean rags, Tire levers, Tubes and Tube patch kit, floor pump with
gauge).

Service Center tools:-

In service center tool can included the complete servicing tool opening the
parts repair defective parts and replacing tools. Following tools are used this
point: (General Work Bench, Pneumatic hanger tools, multi-jet part washer,
Engine Workstation, compressor, bench grinder, Pneumatic Panel Board, Tool
Trolley)

Pneumatic panel Board Some Useful tools

General Workbench Two Wheeler hydraulic lift Two wheeler tool boards
Technical Content:-

ENGINE AND
TRANSMISSION SYSTEM:-
Automatic and semi-automatics typically
use a centrifugal clutch which operates in a
different fashion. At idle, the engine is
disconnected from the gearbox input shaft,
allowing both it and the bike to freewheel.
As the throttle is opened and engine speed
rises, counterweights attached to movable
inner friction surfaces within the clutch
assembly are thrown gradually further
outwards, until they start to make contact
with the inside of the outer housing and
transmit an increasing amount of engine
power. The effective "bite point" is found
automatically by equilibrium where the power being transmitted through the
(still-slipping) clutch is equal to what the engine can provide. This allows relatively
fast full-throttle takeout without the engine slowing or bogging down, as well as
more relaxed starts and low-speed maneuvers at lower throttle settings and
rpms.

Above a certain engine speed - when the bike is properly in motion, so the
gearbox input shaft is also rotating quickly and so allowing the engine to
accelerate further by way of clutch slip - the outward pressure of the weighted
friction plates is sufficient that the clutch will enter full lock-up, the same as a
conventional plate-clutch with a fully released lever or pedal. After this, there is
no clutch slip, and the engine is locked to and providing all of its available power
to the transmission; engine rpm is now dependent on the road speed and the
current gear ratio. In a typical CVT, the gear ratio will be chosen so the engine can
reach and maintain its maximum-power speed as soon as possible, but in a semi-
auto the rider is responsible for this choice, and they can ride around all day in
top gear (or first) if they so prefer. Also, when the engine is turning fast enough to
lock the clutch; it will stay fully engaged until the RPMs fall below that critical
point again, even if the throttle is fully released. Below the lock-up point, partially
or fully releasing the throttle can lead to the RPM falling off rapidly, thanks to the
feedback loop of lower engine speed meaning less friction pressure. This toggle-
like mode of operation can lead to certain characteristic centrifugal-clutch-
automatic behavior, such as being able to freewheel rapidly downhill from a
standstill, with engine braking only being triggered by turning the throttle briefly
(and not then cancellable without braking to quite a slow, gear-dependent pace),
and lockup triggering at a lower speed with full versus minimal throttle.

CAM AND TAPPET

MECHANISM:-
A cam is a rotating or sliding piece in
a mechanical linkage used especially
in transforming rotary motion into
linear motion or vice versa. It is
often a part of a rotating wheel (e.g.
an eccentric wheel) or shaft (e.g. a
cylinder with an irregular shape)
that strikes a lever at one or more
points on its circular path. The cam can be a simple tooth, as is used to deliver
pulses of power to a steam hammer, for example, or an eccentric disc or other
shape that produces a smooth reciprocating (back and forth) motion in the
follower, which is a lever making contact with the cam.

The relationship between the rotation of the camshaft and the rotation of the
crankshaft is of critical importance. Since the valves control the flow of the
air/fuel mixture intake and exhaust gases, they must be opened and closed at the
appropriate time during the stroke of the piston. For this reason, the camshaft is
connected to the crankshaft either directly, via a gear mechanism, or indirectly via
a belt or chain called a timing belt or timing chain. Direct drive using gears is
unusual because of the cost. The frequently reversing torque caused by the slope
of the cams tends to cause gear rattle which for an all-metal gear train requires
further expense of a cam damper. Where gears are used in cheaper cars, they
tend to be made from resilient fibre rather than metal, except in racing engines
that have a high maintenance routine. Fibre gears have a short life span and must
be replaced regularly, much like a timing belt. In some designs the camshaft also
drives the distributor and the oil and fuel pumps. Some vehicles may have the
power steering pump driven by the camshaft. With some early fuel injection
systems, cams on the camshaft would operate the fuel injectors.

SPRING LOADED
VALVES & SPARK-
PLUG
ARRANGEMENT:-
A poppet valve (also called
mushroom valve) is a valve
typically used to control the
timing and quantity of gas or
vapor flow into an engine.

It consists of a hole, usually

round or oval, and a tapered
plug, usually a disk shape on the end of a shaft also called a valve stem. The
portion of the hole where the plug meets with it is referred to as the 'seat' or
'valve seat'. The shaft guides the plug portion by sliding through a valve guide. In
exhaust applications a pressure differential helps to seal the valve and in intake
valves a pressure differential helps open it. Poppet valves date from at least the
1770s, when James Watt used them on his steam engines.
Housing and Crank Case:-
In an internal combustion engine of
the reciprocating type, the crankcase is
the housing for the crankshaft. The
enclosure forms the largest cavity in the
engine and is located below the
cylinder(s), which in a multicylinder engine
is usually integrated into one or several
cylinder blocks.

Crankcases have often been discrete parts, but more often they are integral with
the cylinder bank(s), forming an engine block. Nevertheless, the area around the
crankshaft is still usually called the crankcase. Crankcases and other basic engine
structural components (e.g., cylinders, cylinder blocks, cylinder heads, and
integrated combinations thereof) are typically made of cast iron or cast aluminum
via sand casting. Today the foundry processes are usually highly automated, with
a few skilled workers to manage the casting of thousands of parts.

Besides protecting the crankshaft and connecting rods from foreign objects, the
crankcase serves other functions, depending on engine type. These include
keeping the motor oil contained, usually hermetically or nearly hermetically (and
in the hermetic variety, allowing the oil to be pressurized); providing the rigid
structure with which to join the engine to the transmission; and in some cases,
even constituting part of the frame of the vehicle.

PISTON CYLINDER ARRANGEMENT

A cylinder is the central working part of a
reciprocating engine or pump, the space in
which a piston travels. Multiple cylinders are
commonly arranged side by side in a bank,
or engine block, which is typically cast from
aluminum or cast iron before receiving
precision machine work. Cylinders may be
sleeved (lined with a harder metal) or
sleeveless (with a wear-resistant coating such as Nikasil). A sleeveless engine may
also be referred to as a "parent-bore engine".

A cylinder's displacement, or swept volume, can be calculated by multiplying its

cross-sectional area (the square of half the bore by pi) by the distance the piston
travels within the cylinder (the stroke). The engine displacement can be
calculated by multiplying the swept volume of one cylinder by the number of
cylinders. A piston is seated inside each cylinder by several metal piston rings
fitted around its outside surface in machined grooves; typically two for
compressional sealing and one to seal the oil. The rings make near contact with
the cylinder walls (sleeved or sleeveless), riding on a thin layer of lubricating oil;
essential to keep the engine from seizing and necessitating a cylinder wall's
durable surface.

FIN:-A spark plug (sometimes, in British English, a sparking plug, and,

colloquially, a plug) is a
device for delivering
electric current from an
ignition system to the
combustion chamber of a
spark-ignition engine to
ignite the compressed
fuel/air mixture by an
electric spark, while
containing combustion
pressure within the
engine. A

Spark plug has a metal

threaded shell, electrically
isolated from a central electrode by a porcelain insulator. The central electrode,
which may contain a resistor, is connected by a heavily insulated wire to the
output terminal of an ignition coil or magneto. The spark plug's metal shell is
screwed into the engine's cylinder head and thus electrically grounded. The
central electrode protrudes through the porcelain insulator into the combustion
chamber, forming one or more spark gaps between the inner end of the central
electrode and usually one or more protuberances or structures attached to the
inner end of the threaded shell and designated the side, earth, or ground
electrode(s).

Some common problems that we face in regular basis & then will try to come
out with solutions:-

Motorcycle Engine Halting At The Middle of The Road or Not Starting At

All:-

Usually one can experience a problem during the cold start of a bike,
especially if it is being started after a certain period of delay. There can be
various reasons for this. The most common reason can be engine is not
getting sufficient fuel to start which now takes us to the carburetor ( as it is
still widely used in our bikes).

A simple choke can help you in starting it. If the problems still follow then
check your fuel line. Another reason can be bad quality fuel which I am sure
almost all the bikers have faced. If there is no problem there then you will
like to take a look at the spark plugs, what their condition is, whether you
are getting enough sparks to run the engine. If still it doesnt start up, then
buddy I afraid you have a problem in the coil or engine which in most cases
will need assistance of a mechanic.

If you are experiencing a halt in the middle of a long run than First Park
your bike in a safe place. Now look for the fuel line, see if there is any
problem there. The quality of fuel also matters here. If you are riding a
lower cc bike at a constant high speed then engine may over heat & stop.
Give her some time to cool things up. If it has point system then you should
check the plugs & if your bike has a CDI ignition then you should check
whether its getting sufficient amount of current it needs.

Not Getting A Good Throttle Response:-

If you are not getting a good throttle response then there are couple of
things you can check for. For instance first thing will be the carburetor
tuning along with the engine tuning. Check for the air filter, fuel filter & the
spark plugs. If the problem still persists then you should check the quality of
the fuel too. Now these are the major things you should check for first.
 To make your observation vaster you can also check the spark or the CDI or
the coils whether they are providing enough sparks at the right time. You
can also check your acceleration cable. We often forget about it but as time
passes by, rusts start building inside the cable as it is prone to open air. You
can also check whether your clutch plates are ok or not.

Motorcycle Braking Problems:-

I believe this is the most essential part of any moving vehicle. I remember
when I first learnt to drive a car, my uncle taught me; it is not about how
fast you can go, it is about how smoothly you can break even cruising at a
very high speed. In our country we have two kinds of brakes. One is Drum
brakes & the other is Disk brakes which r controlled by Hydraulic fuel. Lets
talk about Drum brakes first. If you are facing a problem in braking system
then the first thing you need to see is the brake cable. If it is old, change it.
It may rust inside & tangle when you are braking thus not providing good
support. You should monitor the brake pads regularly. If you are using drum
brakes then I will suggest not riding aggressively when you are riding for a
very long time. More braking means the pads will get hotter & expand
more which can result in poor braking. Check for the brake drums as they
can wear & tear with daily riding thanks to our climate.

In disk brakes, first of all check for the Hydraulic fuel, whether its reaching
the drums properly. Use only recommended fuel. Also check the buckets in
the levers. Give the brake shoes a regular checking.
 Electrical Problems:-

Now this is a common problem for bikes. As it is naked therefore more

prone to dust & rain. Electrical problems can cause severe issues for bikes.
From a nonworking indicator light to halting the whole engine, everything is
related to electrical problems. First thing to avoid this kind of problems will
be, whenever you have to cut an electric wire, make sure you are doing it
right. A wrong connection can end up your bike on fire.

Please check that all the ends are properly taped after being cut. Check
your battery regularly. Do not forget to check whether the coils are working
properly or not. It can make a vast impact on your bikes performance,
throttle response & mileage. Last but not the least, if you go to mechanics
for wiring problems; please do not go at night. Work on it in the morning
when he will have sufficient lights to see whether he is working with the
right wire or not, this is my personal opinion.

Strong Vibrations or Jerking At Top Speed:-

Almost all bikes have a minimum vibration which I am sure you are aware
of. But if your bike is having an excessive amount of vibrations then there
can be couple of things you can look for as it heavily affect your riding
capabilities, especially when riding at a high speed. First of all, you should
check whether all the bikes body parts are properly joined or not,
especially if it is a Chinese full faired bike.

One point I will like to note here is, one should check the seat bolts
whether they are properly bolted. This is something we dont check a lot
but it can really hamper a good ride. We can also check the shock absorbers
& the suspensions whether they are properly working or not. If they are oil
based suspensions then check for the oil level. Another reason can be a
worn out chain sprocket or the whole chain set which results a wobbling
effect. My personal advice will be, if you are going to just change the chain,
then try to change the whole set because it will give your chain a longer life
time.
 High Fuel Consumption:

Now this is something which concerns all the bikers as the price of fuel is
hiking sky high. First of all, it depends on the way you ride your bike. Proper
gear shifting & riding at a constant speed can really give you a high mileage.
But this is just one part of getting a good economy. There are some small
but important factors too. Proper changing of engine oil can really help you
in getting a good mileage. A good tuning in carburetor is very much
important too.

You should also check out your clutch plates. The radials play a vital role
too. Less air pressure in radials can increase your fuel consumption. Your
tires should move along smoothly. Chain sprockets, break shoe problems,
drum problems; bearings can also play a major role in the
fuel consumptions.