MEASURING INSTRUMENTS

Objectives

After completion of the practical classes the students should be able to:

 Explain about outside micrometer, inside micrometer and veriner caliper

 Take measurements with outside micrometer, inside micrometer and veriner caliper.

SITTTR, Kalamas sery

EXERCISE NO. 1
MEASUREMENT WITH OUTSIDE MICROMTER

Aim:

To familiarize with outside micrometer by measuring the diameter of piston pin.

Tools required:

Outside micrometer.

Materials required:

Piston pin.

Procedure:

 Before taking measurements make sure that the instrument has no zero error.

 Place the piston pin in between the spindle and the anvil.

 Turn the thimble until the instrument touches the piston pin.

 Then turn the ratchet until it slips.

 Lock the instrument.

 Take the main scale reading(MSR) and the thimble scale reading(TSR).

 Calculate the diameter of the piston pin. ( Diameter = MSR+(TSR x LC).

 Take two more readings calculate the mean value,

Result:

Diameter of the piston pin = ———————— mm

SITTTR, Kalamas sery

OUTSIDE MICROMETER

Fig.E.1

Least count (LC) = One main scale division value = 0.5/50 = 0.01mm.

No. of thimble scale divisions

TABULATION

Trial No. MSR TSR Diameter = MSR + (TSR x LC)

(mm) (mm)

Mean

SITTTR, Kalamas sery

EXERCISE NO. 2
MEASUREMENT WITH INSIDE MICROMETER
Aim:

To familiarize with inside micrometer by measuring the bore of an engine cylinder.

Tools required:

Inside micrometer, ring spanner set, open ended spanner set, socket spanner set, screw

driver, etc,

Materials required:

single cylinder engine,

Procedure:

 Remove the cylinder head from the engine.

 Keep the piston below the TDC position.

 Insert the micrometer into the cylinder and turn the thimble until it touches the
cylinder wall.

 Lock the instrument and take out it.

 Take the main scale reading(MSR) and the thimble scale reading(TSR)..

 Calculate the bore of the engine cylinder. ( bore = MSR + (TSR x LC).

 Take two more readings and calculate the mean value.

 Refit the cylinder head to the engine.

Result:

Bore of the engine cylinder = ———————mm.

SITTTR, Kalamas sery

INSIDE MICROMETER

Fig.E.2

Least count (LC) = One main scale division value = 0.5/50 = 0.01mm.

No. of thimble scale divisions

TABULATION

Trial No. MSR TSR Diameter = MSR + (TSR x LC)

(mm) (mm)

Mean

SITTTR, Kalamas sery

EXERCISE NO. 3

MEASUREMENT WITH VERNIER CALIPER

Aim:

To familiarize with the vernier caliper by measuring the diameter of piston skirt.

Tools required:

Vernier caliper.

Materials required:

Piston.

Procedure:

 Place the piston skirt in between the jaws of the instrument.

 Apply thumb pressure on the movable jaw until it touches the piston skirt.

 Lock the instrument and take it from the piston.

 Note the main scale reading (MSR), the division just before the zero of the vernier scale
and the vernier scale reading (VSR), the vernier scale division which coinciding with any
of the main scale division.

 Calculate the diameter of the piston skirt (diameter = MSR + (VSR x LC ).

 Take two more readings and calculate the mean value.

Result:

Diameter of the piston skirt = ——————mm.

SITTTR, Kalamas sery

VERNIER CALIPER

Fig.E.3

Least count (LC) = one main scale division value = 1/50 = 0.02mm.

No. of vernier scale divisions

TABULATION

Trial No. MSR VSR Diameter = MSR + (VSR x LC)

(mm) (mm)

Mean

SITTTR, Kalamas sery

 VEHICLE SERVICING
Objectives:

After the completion of the practical class the student should be able to understand the
washing and the greasing procedure of motor vehicles.

EXERCISE NO. 4
SERVICING OF VEHICLE

Aim:-

To study about the water servicing and greasing of vehicles.

Tools and equipment required:-

Car washer, air compressor, grease gun, spanner set etc.

Materials required:-

Diesel, liquid soap/ teepol, grease, cotton waste.

Procedure:-

 Park the vehicle on the washing ramp and block the wheels.

 Spray water to the vehicle with the washing gun ( to the body, under body and engine
room in case of three wheelers).

 Apply diesel to the lower portions of the vehicle body to remove the tar particles.

 Apply liquid soap/teepol to the vehicle surface.

 Again spray water to the vehicle.

 Wipe the vehicle with clean cotton waste.

 Apply grease wherever it is needed.

 Check the tightness of the nuts and bolts and correct the tightness if needed.

 Start the vehicle and remove from the washing ramp.

 Finally make sure that the functioning of the lights and the other accessories are
correct.

SITTTR, Kalamas sery

 DISMANTLING AND ASSEMBLING ENGINES

Objectives:

After the completion of the practical classes the student should be able to:

 Understand the working of engines.

 .Explain the functions orf each components.

 .Dismantle and assemble four stroke engines.

EXERCISE NO. 5
DISMANTLING AND ASSEMBLING OF FOUR STROKE PETROL
ENGINE
Aim:

To study about the parts and the working of four stroke petrol engine.

Tools required:

Open ended and ring spanner sets, socket spanner sets, spark plug spanner, screw driver,
hammer, circlip pliers, scrapers, piston ring expander, bearing puller, torque wrench, etc.

Materials required:

Kerosene, cotton waste, engine oil, grease.

Procedure:

Dismantling:-
 Place the motor cycle on the work platform.
 Drain the engine oil.

 Disconnect the electric connections.

 Disconnect the clutch cable connection.

 Remove inlet manifold and the muffler.

 Remove the engine side sprocket wheel and there by the chain connection.

 Take out the engine from the vehicle.

 Place the engine on a work bench and remove the gear shifting lever and the kicker.

SITTTR, Kalamas sery

 Remove the spark plug.

 Remove the clutch assembly.

 Remove the flywheel magneto assembly.

 Remove the timing chain.

 Remove cylinder head from the cylinder block.

 Remove the piston from the connecting rod.

 Remove the cylinder block from the crankcase.

 Split the crankcase and take out the crankshaft with connecting rod.

 Remove the connecting rod and the bearing from the crankshaft.

 Clean all parts with kerosene.

 Inspect for the damage and wear and tear, and rectify.

Assembling:-
 Install connecting rod and bearings to the crankshaft.

 Refit the piston to the connecting rod

 Refit the piston- connecting rod assembly to the crankshaft.

 .Insert bearings to the crankshaft.

 Install crankshaft to the crankcase.

 Refit the clutch assembly and the flywheel magneto assembly,

 Refit the cylinder block.

 Connect the crankshaft to the camshaft with the timing chain.

 Refit the spark plug,

 Refit the gear shifter lever and the kicker.

 Refit the engine to the vehicle and reconnect clutch and the electric connections.

 Refit the muffler and the inlet manifold.

 Refit the engine side sprocket wheel and connect the drive chain to it.

 Refill the engine with engine oil and maintain the specified level.

 Ensure the proper working of the engine and finish the work.

SITTTR, Kalamas sery

 Fig.E.4

SITTTR, Kalamas sery

EXERCISE NO. 6
DISMANTLING AND ASSEMBLING OF TWO STROKE PETROL
ENGINE
Aim:

To study about the parts and the working of two stroke petrol engine.

Tools required:

Open ended and ring spanner sets, socket spanner sets, spark plug spanner, screw
driver, hammer, circlip pliers, scrapers, piston ring expander, bearing puller, torque wrench, etc.

Materials required:

Kerosene, cotton waste, engine oil, grease.

Procedure:

Dismantling:-
 Place the autorikshaw on the workshop floor.

 Open the engine room.

Drain the lubricating oil.

 Disconnect the cable(accelerator, clutch, gear shifter), electric and fuel connections.

 Remove the drive shafts from the differential.

 Take out the engine assembly from the vehicle.

 Remove the gear shifter. Remove

 Remove the clutch cover.

 Remove the clutch assembly from the engine shaft.

 Remove the cylinder head.

 Remove the cylinder block.

 Remove the differential unit.

 Split the crankcase.

 Take out the piston-connecting rod-crank shaft assembly from the crankcase half.

 Remove the piston from the connecting rod.

SITTTR, Kalamas sery
  Remove the connecting rod from the crank shaft

 Clean all parts with kerosene.

 Inspect for the damage and wear and tear, and rectify.
Assembling:-

 Refit the connecting rod to the crank shaft.

 Refit the piston to the connecting rod.

 Refit the piston-connecting rod-crank shaft assembly to the crankcase half.

 Assemble the crankcase halves.

 Refit the cylinder block to the crankcase.

 Refit the cylinder head to the cylinder block.

 Refit the clutch assembly to the engine shaft.

 Refit the clutch cover.

 Refit the gear shifter.

 Refit the differential unit.

 Refit the drain nut.

 Refit the engine assembly in the vehicle.

 Connect the drive shafts to the differential.

 Connect the cable, electric and fuel connections to the engine assembly.

 Refill the lubricating oil up to the allowed maximum level.

 Close the engine room.

 Ensure the proper working of the engine and finish the work.

SITTTR, Kalamas sery

 Fig.E.5

SITTTR, Kalamas sery

 FUEL SYSTEM

Objectives:

After the completion of the practical work the student should be able to:

 Explain the various components of gravity feed petrol fuel system.

 Dismantle, clean and assemble the carburettor.

 Adjust idle speed.

EXERCISE NO. 7

SERVICING OF PETROL FUEL SYSTEM (GRAVITY FEED)

Aim:

To study about the petrol fuel system and its maintenance.

Tools required:

Spanner set, screw driver set, nose pliers, tray, etc,

Materials required:

Cotton waste, petrol, cleaning solution (brake fluid).

Procedure:

 Place the vehicle on the work platform.

 Remove the side and take out the air filter element.
 Lock the fuel line and take out the fuel filter.
 Disconnect the fuel and cable connections to the carburettor.
 Remove the carburetor from the vehicle.
 Dismantle the carburettor and remove the fuel orifices and jets.
 Clean all the parts with suitable cleaning solution.
 Clean the passages with compressed air and also the jet and
orifice holes.

SITTTR, Kalamas sery

 Refit the fuel jets and orifices to the carburettor body and assemble the carburettor.

 Refit the carburettor to the vehicle.

 Clean and inspect the fuel filter. If it is good in condition, refit it ,otherwise replace

it.

 Reconnect the removed cables and fuel line.

 Clean the air filter element with compressed air and refit it, (if the element is

clogged, replace it).

 On the fuel supply and start the vehicle.

 Adjust the slow speed of vehicle.

 Ensure the proper working of fuel system and finish the work.

Fig.E.6 Cable Controlled Carburettor

SITTTR, Kalamas sery

 Lubrication System

Objectives:
After the completion of the practical work the student should be able to:

 Explain the components of lubrication system and its function.

 Clean and inspect oil filter.

 Overhaul the oil pump.

EXERCISE NO. 8
OVERHAULING OF LUBRICATION SYSTEM ( TWO WHEELER- 4
STROKE)
Aim:

To study about the lubrication system

Tools :

Spanner set, Screw Drivers, Nose pliers, Tray

Materials required :

Engine oil, Gasket, Cotton waste, Grease

Procedure:
1. Place the vehicle on the work platform

2. Drain the oil

3. Remove the crankcase side cover

4. Remove the filter

5. Remove the oil pump

6. Dismantle the oil pump.

7. Clean the filter element and the dismantle the parts

8. Inspect for wear and tear

9. Assemble the oil pump

SITTTR, Kalamas sery

10. Refit the filter

11. Refit the pump

12. Refit the crankcase side cover with new gasket

13. Refit the drain nut

14. Refill the oil and maintain the oil level

15. Ensure the proper functioning of lubrication system.

Fig.E.7 Gear type oil pump

SITTTR, Kalamas sery

 SUSPENSION SYSTEM

Objectives:

After the completion of the practical work the student should be able to:

 Explain the components of suspension systems and its functions.

 Overhaul suspension systems

EXERCISE NO. 9
SERVICING OF FRONT SUSPENSION OF MOTORCYCLE
(TELESCOPIC FORK)
Aim:-

To study about the working, and the maintenance of telescopic fork suspension.

Tools Required:-

Spanner set, socket set, screw driver, hammer, allen key set, torque wrench, etc.

Materials Required:-

Cotton waste, fork oil

Procedure:-
 Place the vehicle on the work platform.

 Disconnect the speedometer and the brake cables at the front wheel side.

 Remove the front wheel from the vehicle.

 Take out the fork assembly from the vehicle.

 Remove the dust boot from the fork assembly.

 Remove the fork cap and drain the fork oil.

 Take out the distance tube and the fork spring from the fork tube.

 Take out the fork piston and the rebound spring from the fork tube.

 Remove the fork tube from the slider.

 Remove the oil seal from the slider.

 Clean all dismantled parts and inspect them for wear and tear and damages.

SITTTR, Kalamas sery

 Insert a new oil seal inside the slider.

 Insert the rebound spring and the fork piston in the fork tube.

 Install the fork tube in the slider.

 Insert the fork spring and the distance tube in the fork tube.

 Fill the fork tube with fork oil.

 Refit the fork cap.

 Refit the dust boot.

 Refit the fork assembly to the vehicle.

 Refit the front wheel.

 Reconnect the brake and the speedometer cables.

 Adjust the front brake.

 Ensure the proper working of front suspension and then finish the work.

Fig.E.8 Telescopic Fork Suspension

SITTTR, Kalamas sery

EXERCISE NO. 10
SERVICING OF REAR SUSPENSION OF AUTORIKSHAW (LEAF SPRING)

Aim:-

To study about the working, and the maintenance of leaf spring suspension.

Tools Required:-

Spanner set, socket set, screw driver, hammer, screw jack, torque wrench, levers, safety
stands, etc.

Materials Required:-

Cotton waste, graphite penetrating oil.

Procedure:-
 Park the vehicle on the workshop floor and block the wheels.

 Loosen the wheel nuts of rear wheel (any side).

 Jack up the vehicle and support on the safety stand.

 Remove the wheel.

 Support the rear axle on a safety stand and remove the U-bolts.

 Remove the leaf spring assembly from chassis frame.

 Remove the shackle unit from the frame.

 Take out the bushes from the spring eyes.

 By removing the steel clamps and the centre bolt, separate the leaves.

 Inspect the leaves, bushes, and pins for wear and tear and damages.

 Assemble the leaves together with the help of steel clamps and centre bolt.

 Insert the bushes in the spring eyes and the shackle.

 Refit the shackle to the chassis frame.

 Refit the leaf spring assembly to the vehicle.

 Reconnect the rear axle to the leaf spring assembly and then remove the safety stand.

 Refit the wheel.

 Jack up the vehicle and remove the supporting safety stand.

SITTTR, Kalamas sery
 Jack down the vehicle and tighten the wheel nuts.

 Ensure the proper working of leaf spring suspension and then finish the work.

Fig.E.9 Leaf spring assembly

SITTTR, Kalamas sery

 BRAKES

Objectives:

After the completion of the practical work the student should be able to;

 Explain the parts and working of mechanical and hydraulic brakes.

 Overhaul the mechanical and hydraulic brake systems.

 Adjust the brake.

EXERCISE NO. 11

SERVICING OF MECHANICAL BRAKE (MOTORCYCLE)

Aim:-

To study about the working, maintenance and adjustments of mechanical brake.

Tools Required:-

Spanner set, screw driver, hammer, etc.

Materials Required:-

Cotton waste, emery paper

Procedure:-
 Place the bike on the work platform.

 Disconnect the speedometer and the brake cables at the front wheel side.

 Remove the axle nut and then take out the axle bolt.

 Remove the front wheel from the vehicle.

 Take out the brake shoe assembly from the wheel hub.

 Separate the brake shoes.

 Clean the brake shoe linings and the drum with clean cotton waste.

 Inspect the brake linings brake drum and the cam for wear and tear and damage.

 Refit the brake shoes.

 Rub the brake lining and the drum surfaces with emery paper.

 Refit the brake shoe assembly in the wheel hub.

SITTTR, Kalamas sery
 Refit the wheel.

 Reconnect the brake and the speedometer cables.

 Adjust the front brake.

 Ensure the proper working of front brake and then finish the work.

Fig.E.10 Mechanical brake

SITTTR, Kalamas sery

EXERCISE NO. 12

SERVICING OF HYDRAULIC BRAKE

Aim:-

To study about the working, maintenance and adjustments of hydraulic brake.

Tools Required:-

Spanner set, socket set, screw driver, hammer, rubber hose, bottle, etc.

Materials Required:-

Cotton waste, emery paper, brake fluid and wheel cylinder kits.

Procedure:-
 Park the vehicle on the workshop floor and block the wheels.

 Loosen the wheel nuts.

 Hoist the vehicle and support on safety stands.

 Remove one wheel

 Remove the brake drum.

 Take out the brake shoes from the back plate by removing the retractor springs and the
shoe holding pins.

 After removing the dust boots take out the pistons and the spring from the wheel cylinder.

 Remove the o-rings(seal) from the pistons.

 Inspect the brake linings, brake drum, pistons, wheel cylinder for wear and tear and
damages.

 Insert new o-rings on the pistons.

 Insert spring and pistons in the wheel cylinder

 Then insert new dust boots to the wheel cylinder.

 Refit the brake shoes on the back plate.

 Rub the surfaces of brake linings and brake drum with emery paper.

 Refit the brake drum to the wheel hub.

SITTTR, Kalamas sery
 Repeat this same procedure at all other wheels.

 Fill the master cylinder with new brake fluid and remove the air from the brake system (air
bleeding).

 Refit the wheels and adjust the brakes.

 Jack up the vehicle and remove the safety stands.

 Jack down the vehicle and then tighten the wheel nuts.

 Ensure the proper working the brake system and then finish the work.

Fig.E.11 Hydraulic brake

SITTTR, Kalamas sery

 WHEEL AND TYRE

Objectives:

After the completion of the practical work the student should be able to;

 Explain the parts the tyre.

 Change the tube of the tyre and inflate the tyre.

EXERCISE NO. 13
SERVICING OF TYRE
Aim:-

To study about the tyre and its maintenance work.

Tools Required:-

Screw jack, safety stand, wheel spanner, valve key, hammer, tyre pressure gauge, tyre

levers, etc.

Materials Required:-

Cotton waste, chalk powder.

Procedure:-
 Park the vehicle on the workshop floor and block the wheels

 Loosen wheel nuts of the tyre to be removed.

 Jack up the vehicle and support on a safety stand.

 Remove the wheel by removing the wheel nuts.

 Keep the wheel flat on the floor and deflate it.

 Hammer the tyre at shoulder so that its bead is free from rim on both sides.

 Using tyre levers take out one side tyre bead from the rim.

 Take out the tube from the tyre after unscrewing valve body securing nut.

 Clean the inside of the tyre and apply chalk powder.

 After the inspection insert the tube in the tyre.

 Insert the tyre bead into the rim and secure valve body to the rim.
SITTTR, Kalamas sery
 Inflate the tyre and correct the tyre pressure.

 Refit the wheel to the vehicle.

 Jack up the vehicle and remove the safety stand.

 Jack down the vehicle and tighten the wheel nuts.

Fig.E.12 Cross sectional view of a tubed tyre

SITTTR, Kalamas sery