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1. 158 0 LWB Sup 156 2 SWB Crew Cab 172 4 LWB Cre 18 500 Ibs F 350 Crew Cab DRW 4x2 anc 4x4 with 6 7L Power Stroke Turbo Diesel 7 260 Ibs F 350 DRW 4x2 Regular Cab 14 000 Ibs Bumper to Bumper 3 years 36 000 miles Powertrain 5 years 60 000 miles Safety Restraint System 5 years 60 000 n Corrosion Perforation only 5 years Unlin Roadside Assistance Program 5 years 60 Lecture Hour 4 Technical Specifications of Delivery van Bajaj GC Max 1000 We dealing in Bajaj GC 1000 pick up which is widely accepted for its convenience in the cargo carrier segment The vehicle has very high efficiency and capable of taking great loads in the commercial goods transportation Technical specifications Type Cooling Type Displacement Max Power Max Torque Ignition Type Transmission Type Clutch Type System Chassis Type Engine Four Stroke Single Cylinder IDI Compression Ignition Forced Air Cooled 416 cc 8 5 bhp 6 25 kW 3600 rpm 20 Nm 2400 rpm Electric start 4 forward amp 1 reverse gear Single plate dry friction type foot operated Electrical System System 12V DC Chassis Semi Monocoque Suspension 44 Front Antidive leading link with helical compression spring amp shock Suspension absorber Rear Suspension Independent suspension with spring amp shock absorber Tyres Front Tyre Size Front Tyre Size Rear Tyre Size 4 5x10 8PR Brakes Front Brakes Hydraulic brakes
2. The shock absorber usually consists of two parts a spring and a damper or dashpot The spring may be implemented with a steel or titanium coil an elastomer or even compressed air The choice of spring material has a fundamental effect on the characteristics of the fork as a whole Coil spring forks are often heavier than designs which use compressed air springs however they are more easily designed to keep a linear spring rate throughout their travel Substituting titanium coils in favor of steel coils in a design can decrease the weight of the design but leads to an increase in expense Air springs work by utilizing the characteristic of compressed air to resist further compression As the spring is provided by the compressed air rather than a coil of metal they can often be made lighter this makes their use more common in cross country designs Another advantage of this type of fork design is that the spring rate can easily be adjusted by adjusting the pressure of the air in the spring This allows a fork to be effectively tuned to a rider s weight One disadvantage of this design is the difficulty in achieving a linear spring rate throughout the fork s action As the fork compresses the air held inside the air spring also compresses towards the end of the fork s travel further compression of the fork requires ever increasing compression of the compressed air with the spring This results in an increase in spring rate Increasing the volume
3. constructed The only possible modification after the fact is an adjustment that allows the shaft speed to increase along with a corresponding reduction in torque In a situation where multiple speeds are needed a transmission with multiple gears can be used to increase torque while slowing down the output speed This design is commonly found in automobile transmissions The same principle can be used to create an overdrive gear that increases output speed while decreasing torque Lecture Hour 6 Shock Absorber A Two Wheeler Shock Absorber is a mechanical device meant to smooth out or damp a sudden shock impulse and dissipate kinetic energy It is also known as Damper Shock absorbers must absorb or dissipate energy Functions of Two Wheeler Shock Absorbers e They absorb the shock from bumps on the road and helps to make riding safe and smooth e They allow the use of soft springs while controlling the rate of suspension movement in response to bumps e They also along with hysteresis in the tire itself damp the motion of the unsprung weight up and down on the springiness of the tire e Shock Absorber system make the vehicle manageable TERENA F Fully Threaded Outer Body Materials used for making Shock absorbers The most commonly used materials for making these absorbers are e Steel e Aluminum Maintenance of Shock Absorbers e It should be checked regularly e Oils should be changed according to the recommended
4. piston back to cylinder bore of caliper till both caliper piston and piston ring come into their original shape At this time retraction spring pushes the brake pads to their original position The return spring in master cylinder assembly pushes the master cylinder piston back into its original position and allows the fluid to flow back to reservoir via hosepipe and master cylinder bore Advantages of Disk Brake e Disk brake requires less effort brake torque to stop the vehicle compare to drum brake e t generates less heat compare to drum brake for the same brake torque e Ease of maintenance as disk brake is outside the wheel rim e t cools down faster compare to drum brake e f worn out brake shoes are not changed at proper time it can cut the 24 brake drum in drum brake Disk brake does not have such problem e tis less likely to skid compare to drum brake in wet condition e tis much safer than drum brake in hard braking condition Under such condition drum brake can lock up the rear wheel e It has brake pad wear indicator which is not there in drum brake Disadvantages of Disk Brake e tis expensive compare to drum brake e More skills require to operate disk brake compare to drum brake that s the reason why some people are not comfortable with disk brake e fany air remains in disk brake system it can cause accident as the brake will not work effectively e Disk brake assembly has more moving parts and much com
5. Ignition System ignition Head Lamp 12V 35 35W 29 Tail Lamp 12V SW Brake Lamp 12V 10W Speedo Lamp 12V 3 4W Horn 12V AC type Indicator Lamp 12V 5W Suspension Front Oil filled telescopic spring assisted shocks Rear Adjustable hydraulic spring arm shocks Dimensions amp Weights Wheelbase mm 1222 Dry Unladen Weight 75 kg Gross Vehicle Weight 205 kg Fuel Tank Capacity 4 Itr incl 1 Itr reserve Tyre Size Fr amp Rr 2 5 x 16 Brake Drum Front mm 80 dia Rear mm 110 dia Lecture Hour 3 Technical specification of Scooter Technical specification of LML Vespa Engine Specifications e LML Vespa NV amp Select II Displacement 150 cc 2 Stroke Three Port Disc Valve 8 2 BHP 5500 rpm Vespa 150 62 amp 69 Displacement 150cc 2 Stoke Single Cylinder 6 25 BHP 5000 rpm e LML Vespa Alfa Displacement 110cc e Lambretta Displacement 150cc 2 Stroke Single Cylinder 6 5 BHP 5300 rpm e Vespa PVX Displacement 100cc 2 Stroke Single Cylinder 4 5 BHP 5500 rpm e Vespa 150 62 amp 68 Displacement 150cc 2 Stroke Engine Misc 30 e N A Turbocharger amp Induction e Stock Fuel amp Tuning e HP Unleaded Castrol 2 T Engine Oil Exhaust e Stock Drivetrain e 4 Forward Gears Wet Clutch plate Weight reduction amp transfer e N A Suspension wheels amp tires Suspension wheels amp tires Front suspension type Single Sided Trailing Link S
6. a good few bump starts still have the same Red Flash 47 Battery and same starter motor 5 years on and they are working OK Fuses Make sure you know where all the fuses and relays are on your car and which ones will prevent the car from starting if they are blown Wiring If your battery is in good condition the next check is the wiring There is a main power cable that runs from the battery direct to the starter motor Ensure this is in good condition Similarly check the earth strap from the battery to the chassis and don t forget to check the strap that goes from the engine to the chassis too If you are not familiar with the layout for your car DON T wait until it fails to start before trying to figure out what goes where One warm sunny Sunday afternoon grab yourself a cup of tea and pretend that your car won t start Locate and identify all the main components and reassure yourself you know what good looks like This makes it much easier on a dark afternoon in November when the starter cable has come adrift from the starter motor and you are trying to remember where it s supposed to go Fuses Make sure you know where all the fuses and Failure to Start If your Morgan won t start check the following 1 Do you have sufficient fuel in the tank 2 Is the engine immobiliser disabled correctly 3 Is the battery fully charged Lecture Hour 9 Service Schedule of Three wheeler ignition system 48 1 COIL 1 0
7. a jet needle is restricted by the jet needle engaging step portion and the jet needle supporting cylindrical portion Lecture Hour 7 Splash Lubrication System The splash system is no longer used in automotive engines It is widely used in small four cycle engines for lawn mowers outboard marine operation and so on In the splash lubricating system oil is splashed up from the oil pan or oil trays in the lower part of the crankcase The oil is thrown upward as droplets or fine mist and provides adequate lubrication to valve mechanisms piston pins cylinder walls and piston rings In the engine dippers on the connecting rod bearing caps enter the oil pan with each crankshaft revolution to produce the oil splash A passage is drilled in each connecting rod from the dipper to the bearing to ensure lubrication This system is too uncertain for automotive applications One reason is that the level of oil in the crankcase will vary greatly the amount of lubrication received by the engine A high level results in excess lubrication and oil consumption and a slightly low level results in inadequate lubrication and failure of the engine Lecture Hour 8 Battery Coil Ignition System amp Magetor ignition system Figure 4 2 shows line diagram of battery ignition system for a 4 cylinder petrol engine It mainly consists of a 6 or 12 volt battery ammeter ignition switch auto transformer step up transformer contact breaker capacitor distr
8. battery terminal at the coil is the same as in a conventional ignition system Electronic ignition systems differ from conventional ignition systems in the distributor component area Instead of a distributor cam breaker plate points and condenser an electronic ignition system has an armature called by various names such as a trigger wheel reluctor etc a pickup coil stator sensor etc and an electronic control module Essentially all electronic ignition systems operate in the following manner With the ignition switch turned on primary battery current flows from the battery through the ignition switch to the coil primary windings Primary current is turned on and off by the action of the armature as it revolves past the pickup coil or sensor As each tooth of the armature nears the pickup coil it creates a voltage that signals the electronic module to turn off the coil primary current A timing circuit in the module will turn the current on again after the coil field has collapsed When the current is off however the magnetic field built up in the coil is allowed to collapse which causes a high voltage in the secondary windings of the coil It is now operating on the secondary ignition circuit which is the same as in a conventional ignition system UNIT Il CHASSIS AND SUB SYSTEMS Lecture Hour 1 Single Plate Clutch A clutch is a mechanical device that provides for the transmission power and therefore usually motion fro
9. efforts known as brake jack also negatively affected early full suspension designs When a rider hit the brakes these early designs lost some of their ability to absorb bumps and this happened in situations where the rear suspension was needed most Lower bail joint The problems of pedal bob and brake jack began to be solved in the early 1990s One of the first successful full suspension bikes was designed by Mert Lawwill a former motorcycle champion His bike the Gary Fisher RS 1 was released in 1990 It adapted the A arm suspension design from sports car racing and was the first four bar linkage in mountain biking This design solved the twin problems of unwanted braking and pedaling input to the rear wheel but the design wasn t flawless Problems remained with suspension action under acceleration and the RS 1 couldn t use traditional cantilever brakes A lightweight powerful disc brake wasn t developed until the mid 1990s and the disc brake used on the RS 1 was its downfall Horst Leitner began working on the problem of chain torque and its effect on suspension in the mid 1970 s with motorcycles In 1985 Leitner built a 21 prototype mountain bike incorporating what became known later as the Horst Link Leitner formed a mountain bike and research company AMP research that began building full suspension mountain bikes In 1990 AMP introduced the Horst link as a feature of a fully independent linkage rear suspension for
10. 1 045 Gear ratio 5th 0 875 Cylinder layout Single Cylinder Battery 12 V 5 0 Ah CHASSIS Frame type Diamond Suspension front rear Telescopic Swingarm Wheelbase 1 334mm Brake type front rear Disc Drum Tire size front rear 100 80 17 140 60 R17 Headlight 12 V 35 35W Caster trail 25 degree 101 mm DIMENSIONS Overall Length x Width x Height 2075mm x 770mm x 1090mm Seat height 790 mm Wheelbase 1 334 mm Minimum ground clearance 160 mm Kerb weight 135 kg Fuel tank volume 12 liters 33 Engine oil volume 1 2 liters Lecture Hour 6 Trouble Shooting of Motorcycle It just cranks and cranks Many things can be responsible for a motorcycle that won t start Some small some bigger Usually it s a minor problem and once corrected the cycle will start properly Following certain procedures can make troubleshooting this problem easier This article will give you general troubleshooting methods but you should be sure to have your factory service manual on hand Beginning The Process The first step in troubleshooting a motorcycle that won t turn over is trying to start the engine Listen and observe carefully to see if the engine doesn t rotate makes unusual noises or has inadequate compression If the engine displays any of these symptoms then the problem is internal and requires a more extensive repair If the engine doesn t turn over in neutral then it has seized or locked up and the problem lies with either crankshaft connec
11. 1 Ballast Resistor Watchpoint 1 02 Bosch Blue Coils Warning 1 03 Checking Your 1 04 Coding Letters C B and S W 1 05 Early Lucas Trouble shooting them Pages 15 25 2 DISTRIBUTOR 2 01 Demystifying 2 02 Vacuum Advance Understanding 3 IGNITION SWITCH 3 01 4 4 Immobilizer Issue 1999 on 3 02 Key Assembly for some LHDs 3 03 Switches 1970s early 1980s 4 PLUS 8 SPECIFIC 5 SPARK PLUGS 5 01 Anti Seize 5 02 Appearance 5 03 Champion Cross Reference 5 04 Champion Part Numbers 5 05 Installing and Removing Them 5 06 NGK Part Numbers 5 07 NGK Cross Reference 5 08 Plus 4 Triumph 5 09 PRIMER 5 10 Torque 6 STARTER 6 01 Checking 6 02 Diagnosis 7 TROUBLESHOOTING 7 01 Coil 7 02 Ignition 7 03 4 4 immobilizer 7 04 Plus 8 Immobilizer 7 05 Starter 7 06 Tachometer 49
12. 38 Irregular running because e Ignition cables loose or damaged e Engine gets too hot causing fuel vapor bubbles to interrupt fuel supply e Contact breaker points oiled or burnt e Supporting pin for contact breaker arm worn e Spark plug or connector or ignition armature defective Engine four strokes and does not accelerate because e Carburetor flooded due to dirty or worn needle e Float is leaking e Exhaust port is clogged with carbon e Carburetor not correctly adjusted or jet loose e Air filter dirty Engine knocks while running at full throttle under load because e Too much engine advance e Excessive carbon deposit in the combustion chamber e Cooling fins dirty Engine backfires or spits into carburetor because e Engine does not get sufficient fuel e Spark plug glowing due to wrong heat value e Spark plug bridged dirty or vitrified e Engine getting wrong fuel air mixture e Glow ignitions Engine does not idle because e Idle screw incorrectly set e Control cable for throttle valve incorrectly set e Ignition armature damaged Engine consumes too much fuel because e Gas tank fuel valve petcock or carburetor leaking e Jet needle or needle jet too worn e Jets too large 39 Engine does not accelerate smoothly because e Low engine power see above somewhere e Clutch plates worn e Clutch plates glazed due to overheating by two people riding moped too high idle speed insufficien
13. Automatic self adjusting levers align the brake pads wear and drums establishing between them a constant air gap Drum Brakes benefits e Durability and reliability e Suitability for heavy applications even on dirt roads and in difficult 23 environments e Variety of options for different vehicles and applications e Simple and priced maintenance and repairs Lecture Hour 3 Disc Brake When a brake lever or pedal is pressed the push rod which is connected to lever or pedal and master cylinder piston pushes the master cylinder piston This movement allows the master cylinder piston to slide and push the return spring inside the bore of master cylinder which generates pressure in reservoir tank At this moment a primary seal allows the brake fluid of reservoir tank to flow over it into the brake hosepipes A secondary seal ensures that the brake fluid does not go other side How A Disc Brake Works wheel attaches here Brake Pads Rotor ue Then the fluid enters in to cylinder bore of caliper assembly via brake hosepipes and pushes the caliper piston or pistons At this time the piston ring moves in rolling shape with piston Then the caliper piston pushes brake pad This movement causes brake pads to stick with brake disc which creates friction and stops the brake disc rotor to rotate This way disk brake system stops or slows down the vehicle When the brake lever or pedal is released the piston ring pushes the caliper
14. UNIT POWER PLANT Lecture Hour 1 INTRODUCTION Heat engine is a machine for converting heat developed by burning fuel into useful work It can be said that heat engine is equipment which generates thermal energy and transforms it into mechanical energy CLASSIFICATION OF HEAT ENGINES 1 Based on combustion of fuel i External combustion engine ii Internal combustion engine External combustion engine Here the working medium the steam is generated in a boiler located out side the engine and allowed in to the cylinder to operate the piston to do mechanical work Internal combustion engine In internal combustion engine the combustion of fuel takes place inside the engine cylinder and heat is generated within the cylinder This heat is added to the air inside the cylinder and thus the pressure of the air is increased tremendously This high pressure air moves the piston which rotates the crank shaft and thus mechanical work is done 2 Based on fuel used 1 Diesel engine 2 Petrol engine 3 Gas engine Diesel engine Diesel is used as fuel Petrol engine Petrol is used as fuel Gas engines propane butane or methane gases are used 3 Based ignition of fuel 1 Spark ignition engine Carburetor type engines 2 Compression ignition engine injector type engines Spark ignition engine a mixture of air and fuel is drawn in to the engine cylinder Ignition of fuel is done by using a spark plug The spark plug prod
15. Wheels Passenger cars normally use rims which are of well based or drop centre design The drop enter is used for mounting and demounting the tyre onto the rim Wheels must be strong enough to carry the mass of the vehicle and withstand the forces that are generated during use The wheel centre must accurately locate the wheel rim centrally on the axle It must also provide the required distance from the centreline of the wheel to the face of the mounting flange This is called offset Offset is important because it brings the tyre centreline into close alignment with the larger inner hub bearing and reduces load on the stub axle 26 This allows the inside of the wheel centre to be shaped to provide space for the brake assembly usually located inside the wheel Ventilation slots allow air to circulate around the brakes The rim must be accurately shaped and dimensioned and strong enough to support the tyre under the load of the vehicle and the forces generated by the motion of the vehicle When inflated the tyre is locked to the rim by tapering the bead seat towards the flange or by safety ridges or humps close to the flange In the event of sudden deflation or blow out safety ridges prevent the tyre moving down into the well This helps maintain control of the vehicle while the brakes are applied Well based rims can also be used on heavy commercial vehicles for tubeless tyres Lecture Hour 6 Spoked Wheel UNIT IV TWO WHEELERS Lectu
16. ally of aluminum or steel rims with spokes Brakes Generally there are two independent brakes on a two wheeler one set on the front wheel and one on the rear however there are many models which have linked brakes and apply both at the same time The front brake is generally much more powerful than the rear brake Brakes can either be drum or disc based When the rider operates one of the brakes a fluid element known as hydraulics is pressurized to provide the required forces to squeeze the brake pad material onto the rotor and slow down or stop the vehicle GEAR BOX A gear is a toothed wheel designed to transmit the force to another gear or toothed component The teeth of a gear is known as cogs They are shaped to minimize wear vibration and noise and at the same time maximize the efficiency of power transmission Gears of different size the larger one is called a wheel and the smaller one is called a pinion are used in pairs so that the force of the driving gear can produce a larger force in the driven gear that also at a lower speed or it can be for the purpose of producing a smaller force at a higher speed Lecture Hour 5 Gear Box The motorcycle gear box contains a number of gears in different sizes In the process of gear switching different pairs of gearwheels lock together A large and small wheel lock together in the lowest or slowest gear Similar size wheels lock together in the highest or fastest gear The motorcy
17. and exhaust are completed in two strokes of the piston i e One revolution of the crankshaft There is no valve in this type of engine Gas movement takes place through holes called ports in the cylinder The crankcase of the engine is air tight in which the crankshaft rotates Upward stroke of the piston Suction Compression When the piston moves upward it covers two of the ports the exhaust port and transfer port which are normally almost opposite to each other This traps the charge of air fuel mixture drawn already in to the cylinder Further upward movement of the piston compresses the charge and also uncovers the suction port Now fresh mixture is drawn through this port into the crankcase Just before the end of this stroke the mixture in thecylinder is ignited by a spark plug Fig 2 c amp d Thus during this stroke both suction and compression events are completed Downward stroke Power Exhaust Burning of the fuel rises the temperature and pressure of the gases which forces the piston to move down the cylinder When the piston moves down it closes the suction port trapping the fresh charge drawn into the crankcase during the previous upward stroke Further downward movement of the piston uncovers first the exhaust port and then the transfer port Now fresh charge in the crankcase moves in to the cylinder through the transfer port driving out the burnt gases through the exhaust port Special shaped piston crown deflect the inc
18. cle gear box is the component that makes the actual ratio between the engine and the driving wheels It is also referred to as transmission gear Types of Motorcyle Gear Box In a general manner the motorcycle gear box can be of three types they are e Horizontally Split It has a seam on the horizontal plane e Vertically Split It has a seam on the vertical plane e Cassette Type The gears are loaded in from one side Characteristics of Gear Box The gears are constantly meshed with one another and they are always spinning Uses of Gear Box e t controls gear and shaft alignment e It controls the engine RPM e t protects the gears and lubricants from water dust and other environmental contaminants Function of Gear Box A gearbox is a mechanical method of transferring energy from one device to another and is used to increase torque while reducing speed Torque is the power generated through the bending or twisting of a solid material This term is often used interchangeably with transmission FWD CRANKSHAFT 7 l CLUTCH Main Shaft n 1 Counter Shatt It is located at the junction point of a power shaft the gearbox is often used to create a right angle change in direction as is seen in a rotary mower or a helicopter Each unit is made with a specific purpose in mind and the gear ratio used is designed to provide the level of force required This ratio is fixed and cannot be changed once the box is 16
19. cylinders in one revolution When the contact breaker opens the contact the magnetic field begins to collapse Because of this collapsing magnetic field current will be induced in the secondary winding And because of more turns Q 21000 turns of secondary voltage goes unto 28000 30000 volts The need for higher mileage reduced emissions and greater reliability has led to the development of the electronic ignition systems These systems generate a much stronger spark which is needed to ignite leaner fuel mixtures Breaker point systems needed a resistor to reduce the operating voltage of the primary circuit in order to prolong the life of the points The primary circuit of the electronic ignition systems operate on full battery voltage which helps to develop a stronger spark Spark plug gaps have widened due to the ability of the increased voltage to jump the larger gap Cleaner combustion and less deposits have led to longer spark plug life MAGNETOR IGNTION SYSTEM BETRIELTOR IGHMIOKI BREAKER LEVER f CONTACT n this case magneto will produce and supply the required current to the primary winding In this case as shown we can have rotating magneto with fixed coil or rotating coil with fixed magneto for producing and supplying current to primary remaining arrangement is same as that of a battery ignition system Lecture Hour 9 Electronic Ignition System The need for higher mileage reduced emissions and gr
20. d where combustion takes place The connecting rod connects the piston and the crankshaft The end of the connecting rod connecting the piston is called small end A pin called gudgeon pin or wrist pin is provided for connecting the piston and the connecting rod at the small end The other end of the connecting rod connecting the crank shaft is called big end When piston is moved up and down the motion is transmitted to the crank shaft by the connecting FOUR STROKE ENGINErod and the crank shaft makes rotary motion The crankshaft rotates in main bearings which are fitted the crankcase A flywheel is provided at one end of the crankshaft for smoothing the uneven torque produced by the engine There is an oil sump at the bottom of the engine 2 which contains lubricating oil for lubricating different parts of the engine Lecture Hour 2 FOUR STROKE ENGINE A four stroke engine also known as four cycle is an internal combustion engine in which the piston completes four separate strokes which comprise a single thermodynamic cycle A stroke refers to the full travel of the piston along the cylinder in either direction While risqu slang among some automotive enthusiasts names these respectively the suck squeeze bang and blow strokes they are more commonly termed SUCTION STROKE COMPRESSION STROKE INLET VALVE OPENED POWER STROKE EXHAUST STROKE 1 INTAKE this stroke of the piston begins at top dead center The piston d
21. d with the service center immediately e A starting trouble will indicate insufficient fuel and then feul should be filled in e If horn lights and fuel gauge are troubling the the two wheeler should be taken to the concerned service center and should be serviced accordingly e In addition to proper upkeep and periodical servicing while following the guidelines dikligiently will ensdure that the two wheeler remains in a great condition and comes up with optimal performance e Incase of a front brake one should ensure if the free play and brake fluid levels are fine e Rear Brake Pedal should be regularly checked and ensured that it is free of any trouble e Odor of fuel will indicate a fuel leakage problem and that should be consulted with the service center immediately 41 e A starting trouble will indicate insufficient fuel and then fuel should be filled in If horn lights and fuel gauge are troubling the two wheeler should be taken to the concerned service center and should be serviced accordingly Unit V Three Wheelers Lecture Hour 1 Introduction to Auto Rickshaw Pickup van Delivery van Lecture Hour 2 Technical specification of Auto Rickshaw Bajaj Auto Rickshaw This type of auto rickshaw is in great use for commercial transportation Specially designed for better performance the vehicle is entitled with durability good looks and fuel efficiency Technical specifications Engine Type 2 Stroke Cooling T
22. e Aluminum Maintenance of Suspensions e The suspensions should be checked for loose nuts and bolts and leaks e The swing arm bearings should be lubricated monthly Lecture Hour 8 FRONT SUSPENSION Front suspension is often implemented with a set of shock absorbers in the front fork The suspension travel and handling characteristics vary depending on the type of mountain biking the fork is designed for For instance manufacturers produce different forks for cross country XC downhill DH and freeride riding Suspension fork design has advanced in recent years with suspension forks becoming increasingly sophisticated The amount of travel available has typically increased When suspension forks were introduced 80 100 mm of travel was deemed sufficient for a downhill mountain bike Typically this amount of travel is now more normal for cross country disciplines Downhill forks can now offer in the region of 170 to 203 mm of travel for handling the most extreme terrain Other advances in design include adjustable travel allowing riders to adapt the forks travel to the specific terrain profile eg less travel for uphill sections more travel for downhill sections Advanced designs also often feature the ability to lockout the fork to completely eliminate or drastically reduce the fork s travel for more efficient riding over smooth sections of terrain This lockout can sometime be activated remotely by a cable and lever on the handlebars
23. e hydraulic braking system Bleeding of the system is the means of keeping the hydraulic braking system air free 2 The amount of friction material on the brake pads are very important replacing worn brake pads Is the quickest way to increased the braking power of a vehicle 3 The condition of the brake fluid is very vital 4 The braking system require constant checking and worn and torn parts should be replaced 5 Lubrication is a must to lengthen the life of the brake system parts Parts of a Brake System 22 The important parts of a Brake System are e Brake Pads e Brake Levers e Brake Shoes e Brake Lining e Brake Drums e Sprockets e Brake Wire Line e Brake Cylinder e Brake Fluid Components of Disk brake e brake calipers e brake pads e rotors Lecture Hour 2 Drum brake Typical Orum Brake Paing Brake Cabie Adjusting Sern The principle of operation of drum brakes In the drum brake friction force is due to the fact that under the action of the cam forces the brake pads located inside the inner surfaces are pressed against the brake drums Thanks much private housing pads are well protected from the effects of corrosion water salt dust and dirt sand stones mud even when driving on hard terrain When using the brakes S shaped cam brake cylinder by adjusting the brake lever and the shaft rotates the S shaped cam thereby pressing the brake shoes with linings to the brake drum Adjusting levers
24. eater reliability has led to the development of the electronic ignition systems These systems generate a much stronger spark which is needed to ignite leaner fuel mixtures Breaker point systems needed a resistor to reduce the operating voltage of the primary circuit in order to prolong the life of the points The primary circuit of the electronic ignition systems operate on full battery voltage which helps to develop a stronger spark Spark plug gaps have widened due to the ability of the increased voltage to jump the larger gap Cleaner combustion and less deposits have led to longer spark plug life In some systems the ignition coil has been moved inside the distributor cap This system is said to have an internal coil as opposed to the conventional external one rysia com ELECTRONIC FFT H CONTROL MOOULE 4 i j os ae t DATI r DISTRIBUTOR Qi w J cap span piu SEZ bs Ex ROTOR i p g IGNITION F SWITCH ACE amp A e At vaduv Kos BATTERY ADVANCE MAGNETIC AELUCTOR Z a PICK UP on PAN Electronic Ignition systems are not as complicated as they may first appear In fact they differ only slightly from conventional point ignition systems Like conventional ignition systems electronic systems have two circuits a primary circuit and a secondary circuit The entire secondary circuit is the same as in a conventional ignition system In addition the section of the primary circuit from the battery to the
25. ecture Hour 3 Centrifugal Clutches A centrifugal clutch is a clutch that uses centrifugal force to connect two concentric shafts with the driving shaft nested inside the driven shaft pg Pn y NT 10 S VIN oa f A KU z Dyin 4 w bak Q 1 157 gt A N i 2000 HowStuffWorks The input of the clutch is connected to the engine crankshaft while the output may drive a shaft chain or belt As engine RPM increases weighted arms in the clutch swing outward and force the clutch to engage The most common types have friction pads or shoes radially mounted that engage the inside of the rim of a housing On the center shaft there are an assorted amount of extension springs which connect to a clutch shoe When the center shaft spins fast enough the springs extend causing the clutch shoes to engage the friction face It can be compared to a drum brake in reverse This type can be found on most home built karts lawn and garden equipment fuel powered model cars and low power chainsaws Another type used in racing karts has friction and clutch disks stacked together like a motorcycle clutch The weighted arms force these disks together and engage the clutch When the engine reaches a certain RPM the clutch activates working 14 almost like a continuously variable transmission As the load increases the rom drops disengaging the clutch letting the rpm rise again and reengaging the clutch If tuned properly the cl
26. escends from the top of the cylinder to the bottom of the cylinder increasing the volume of the cylinder A mixture of fuel and air is forced by atmospheric or greater pressure into the cylinder through the intake port 2 COMPRESSION with both intake and exhaust valves closed the piston returns to the top of the cylinder compressing the air or fuel air mixture into the cylinder head 3 POWER this is the start of the second revolution of the cycle While the piston is close to Top Dead Centre the compressed air fuel mixture in a gasoline engine is ignited by a spark plug in gasoline engines or which ignites due to the heat generated by compression in a diesel engine The resulting pressure from the combustion of the compressed fuel air mixture forces the piston back down toward bottom dead centre 4 EXHAUST during the exhaust stroke the piston once again returns to top dead centre while the exhaust valve is open This action expels the spent fuel air mixture through the exhaust valve s Lecture Hour 3 Two Stroke Engine The 2 Stroke Cycle Traki 1 Sirake 2 Exhaust Pa Open Bunt Gages are pushed Gar rE inet Port Open gt Fresh Fueli Mix Fehaust Port ad 3 Enters The Cra kcase Inet Ped Chas Trzzader Port Gal Tipai Traral For Open d h Funda R a SS Andien o on ination a e a Ezhonikt In two stroke cycle engines the whole sequence of events i e suction compression power
27. fficient fuel in the tank 2 Is the engine immobiliser disabled correctly 3 Is the battery fully charged Battery Condition 99 of all starting problems are electrical and most of those are down to insufficient power being available from the battery to start the engine On newer cars with ECUs if the battery isn t delivering sufficient voltage usually at least 10V whilst cranking 13 2V at rest 14 4V whilst idling then the ECU won t allow the car to start likewise if the starter can t crank the engine at sufficient revs around 100 130 rpm If you don t use your car much especially in winter it is a good idea to keep the battery hooked up to a conditioner Starter Motors A quick test with newer cars with ECU s and pre engage starter motors e g Zetec s is to try to bump start them If they fire up with no problems the pre engage starter motor needs to be looked at before determining the battery has a low voltage fault and starving the ECU of power Notes for Zetec engined cars All too common a fault with the Zetec s and an owner can end up paying for a new battery AND a new starter motor The FORD starter motors can develop dry joints which give the same fault that you have described NB battery Volts drop right off when you try to start A good mechanic can re solder the dry joints as the cheapest repair solution have had this happen to me on my way to Le Mans Classic and resolved when returned home days later and
28. he key on Is there gas Is the battery too weak Or a battery connection loose 45 Have spark plug wires fallen off Is the ignition cut off switch in the OFF position Do you have the choke in the appropriate position 2 If the engine stops when you don t want it to Did you hit the cut off switch by mistake Did you run out of gas Did a fuse burn out 3 Odd Steering If the bike begins to feel funny as you go down the road especially in a curve stop as soon as it is safe to pull over and check your tires You may have a flat Check your suspension You may have it adjusted in correctly Your owner s manual is the best reference for proper settings and adjustments 4 Poor Response If you detect any problems with the 3WMC doesn t feel right doesn t handle right doesn t sound right that you can t figure out yourself take it to your dealer Think about the problem a little so you can describe it to the service manager Remember an ounce of prevention is worth about a ton of cure Lecture Hour 7 Equipment Failurs BLOWOUTS If you run tires of good quality keep them at the proper pressure and change them when the tread is worn the chances of having a blowout are small However you must act quickly if it happens to you 1 Do not use the brakes braking hard will only make things worse If you must use some brake apply gradual pressure to the brmaintenanceake on the good tire s and ease over t
29. ibutor rotor distributor contact points spark plugs etc Note that the Figure 4 1 shows the ignition system for 4 cylinder petrol engine here there are 4 spark plugs and contact breaker cam has 4 corners If it is for 6 cylinder engine it will have 6 spark plugs and contact breaker cam will be a perfect hexagon The ignition system is divided into 2 circuits at dkil f 4 Primer el a i Y Aa Lara inated anag ym DaHa be 8 NE EE marti gt C maki zaj ji ET M Dom trio E 1 cy Ly rf KH LF rt Fe PT L Cees cael me FF m k 4gdriacki Primary Circuit It consists of 6 or 12 V battery ammeter ignition switch primary winding it has 200 300 turns of 20 SWG Sharps Wire Gauge gauge wire contact breaker capacitor ii Secondary Circuit It consists of secondary winding Secondary winding consists of about 21000 turns of 40 S WG gauge wire Bottom end of which is connected to bottom end of primary and top end of secondary winding is connected to centre of distributor rotor Distributor rotors rotate and make contacts with contact points and are connected to spark plugs which are fitted in cylinder heads engine earth iii Working When the ignition switch is closed and engine in cranked as soon as the contact breaker closes a low voltage current will flow through the primary winding It is also to be noted that the contact beaker cam opens and closes the circuit 4 times for 4
30. linder head or spark plug loose Decompression Valve dirty or stuck Engine Runs Unevenly or Misfires The problem is listed with the solution is in parentheses There is not enough fuel in the tank Open fuel valve to reserve and fill with gasoline mixture Float leaks Replace float Ignition cable is not properly connected Properly plug spark connector Spark plug is defective Replace spark plug Jet needle is loose Clamp needle in its notch Engine Power Drops Poor Performance Version One The problem is listed with the solution is in parentheses Choke is working all the time Push back choke full throttle Exhaust pipe is clogged Cleaning the muffler Spark plug is defective Replace spark plug Exhaust port is clogged Clean exhaust port Float leaks float needle deformed jams Check all parts of the float chamber and replace if necessary Float needle is loose Clamp needle in its notch Air filter is clogged Clean air filter Spark plug gap is set incorrectly Gap spark plug correctly Version Two Engine power drops Due to dirt because Air filter clogged Exhaust port and transfer ports in cylinder clogged with carbon Thick carbon deposits in cylinder head Exhaust pipe and muffler are dirty Vent on fuel tank cap clogged Spark plug vitrified Due to reduced compression because See Lack of compression under Engine does not start Other Engine Troubles
31. m one component the driving member to another the driven member when engaged but can be disengaged Clutches are used whenever the transmission of power or motion must be controlled either in amount or over time e g electric screwdrivers limit how much torque is transmitted through use of a clutch clutches control whether automobiles transmit engine power to the wheels The three levers also known as release levers or fingers are carried on pivots suspended from the case of the body These are arranged in such a manner so that the pressure plate moves away from the flywheel by the inward movement of a trust bearing The bearing is mounted upon a forked shaft and moves forward when the clutch pedal is pressed Clutch plate with friction lining Spring pate pressure Driving shaft Release level withdrawl finger Knife edge Fig Single Plate Clutch When the clutch pedal is pressed down its linkage forces the thrust release bearing to move in towards the flywheel and pressing the longer ends of the levers inward The axial pressure exerted by the spring provides a frictional force in the circumferential direction when the relative motion between the driving and driven members tends to take place If the torque due to this frictional force exceeds the torque to be transmitted then no slipping takes place and the power is 12 transmitted from the driving shaft to the driven shaft Lecture Hour 2 M
32. make sure there aren t carbon deposits between the electrodes and the plug hasn t been fouled by too much gasoline The check the plug for spark To do this remove the plug from the head run a high tension lead wire from the coil to the plug and ground the metal part of the plug against the cylinder head or engine block Turn the engine over The plug should always fire a blue spark A red or yellow spark indicates a weak point in the ignition system If you don t get a sharp blue spark the plug itself could be bad Retest with a new spark plug No spark or a weak spark can be caused by low battery voltage dirty broken misadjusted spark plug bad spark plug wire or not not making good contact wrong spark plug in use for your model IC igniter trouble neutral starter side stand switch malfunction pickup or ignition coil trouble ignition or engine stop switch that is shorted shorted wiring or a blown fuse If the plugs aren t the problem then the issue lies with the ignition system itself Please refer to your factory service manual for exact ignition system troubleshooting methods Disclaimer Results may vary The owner of this page makes no quarantees nor accepts any responsibility for any damages Lecture Hour 8 Trouble Shooting of Moped Engine Does Not Start Running Engine Stops Version One 36 The problem is listed with the solution in parentheses e Fuel valve is closed Open petcock or switch fuel valve to reser
33. mountain bikes The AMP B 3 and B 4 XC full suspension bikes featured active Horst Link Macpherson strut rear suspensions and optional disc brakes A later model the B 5 was equipped with both the Horst link and a four bar active link suspension featuring up to 125 mm 5 inches of travel on a bicycle weighing around 10 5 kg 23 pounds For 10 years AMP Research manufactured their full suspension bikes in small quantities in Laguna Beach California including the manufacture of their own cable actuated hydraulic disc brakes hubs shocks and front suspension forks UNIT III BRAKES WHEELS AND TYRES Lecture Hour 1 Introduction Brakes are the devices for slowing and stopping the vehicle The braking operation is reverse of the acceleration to the vehicle Purpose of brakes The main purpose of fitting brakes on motor vehicle are as given under i In emergencies to bring the vehicle to rest in the shortest possible distance ii To control the vehicle when it is descending along the hills iii To keep the vehicle in desired position after bringing it in complete rest when there is no deiver To fulfill the above needs two independent braking system are provided in the vehicle a Service brake which is operated by foot padel in regular operation b Emergency brake which os operated by a hand lever while parking the vehicle Some very important aspects about the Braking System are 1 It is important that there is no air in th
34. o a safe spot to stop 2 Ease off on the throttle and slow down gradually rapid deceleration could throw the bike out of control 3 Hold those handlebars firmly a great shuddering may take place as the out of round tire flops against the pavement but you are concerned only with keeping the front wheel s pointed where you want to go until you stop STUCK THROTTLE Most riders have had bad dreams about this but few have experienced the problem That is why all contemporary motorcycles have a cut off switch by the right thumb Just in case Practice using the cut off switch Chances are you will never have a throttle stick but if you do you ll know how 46 to deal with it As you hit the cut off switch squeeze the clutch you will probably be in gear then look for a safe place to coast to a stop BROKEN CLUTCH CABLE Imagine you are cruising along in fifth gear you want to shift down you squeeze the clutch lever and there is no return action It just lies up against the handgrip No fun but not dangerous You can shift the bike without using the clutch lever This is not advisable unless necessary but it can be done Back off on the throttle and shift down a gear If you have a sensitive foot you can probably find neutral before coming to a complete stop If not get set for a jerky halt Lecture Hour 8 Fault Tracing of Three wheeler Failure to Start If your Morgan won t start check the following 1 Do you have su
35. of the air inside the spring can reduce this effect but the volume of the spring is ultimately limited as it needs to be contained within the dimension of the fork leg The damper is usually implemented by forcing oil to pass through one or more small openings or shim stacks On some models the spring the damper or both may be adjusted for rider weight riding style terrain or any combination of these or other factors The two components may be separated with the spring mechanism in one leg and the damper in the other Some manufacturers especially Cannondale have tried other variations including a single shock built into the steering tube above the crown and a fork with just a single leg that has a shock built into it Others have marketed 20 suspension forks that employ linkages to provide the mechanical action instead of relying upon telescoping elements Lecture Hour 9 REAR SUSPENSION Perhaps because front suspension has been easier to implement and more readily adopted it is often assumed and rear suspension is sometimes synonymous with full suspension Full suspension mountain bike technology has made great advances since first appearing in the early 1990s Early full suspension frames were heavy and tended to bounce up and down while a rider pedaled This movement was called pedal bob kickback or monkey motion and took power out of a rider s pedal stoke especially during climbs up steep hills Input from hard braking
36. oming mixture up around the cylinder so that it can help in driving out the exhaust gases During the downward stroke of the piston power and exhaust events are completed Lecture Hour 4 Scavenging Process SCAVENGING PROCESS A basic part of the cycle of an internal combustion engine is the supply of fresh air and removal of exhaust gases This is the gas exchange process Scavenging is the removal of exhaust gases by blowing in fresh air Charging is the filling of the engine cylinder with a supply or charge of fresh air ready for compression With supercharging a large mass of air is supplied to the cylinder by blowing it in under pressure Efficient scavenging is essential to ensure a sufficient supply of fresh air for combustion In the four stroke cycle engine there is an adequate overlap between the air inlet valve opening and the exhaust valve closing With two stroke cycle engines this overlap is limited and some slight mixing of exhaust gases and incoming air does occur a e Exhaust m a A P 1 Bs js inta Ra ME Erhan Exhausi inlet a wth za ESELI number of different scavenging methods are in use in slow speed two stroke engines In each the fresh air enters as the inlet port is opened by the downward movement of the piston and continues until the port is closed by the upward moving piston The flow path of the scavenge air is decided by the engine port shape and design and the exhaust arrangemen
37. or pistons worn broken sticking piston rings damaged head gasket warped cylinder heads weak or broken valve spring or valves that are not properly seated Checking The Ignition System Usually if the engine is getting good compression and the ignition system is in 35 good running order then the engine will start even if it is flooded And so if there is compression and fuel flow but the engine still doesn t start then there is more than likely a problem with the ignition system Start by checking the battery then fuses and switches then the spark plugs and last the ignition system Always check the obvious first Make sure all ignition related switched are in the Run position It s not unusual to find a motorcycle or ATV that won t run because the ignition switches are in the Off position Turn on the lights If they burn brightly then more than likely your battery is charged You can check this with a voltmeter It should be within 0 5 of the specified voltage In other words if you have a 12 volt battery then the voltmeter should read no less than 11 5 volts If the battery is charged and the lights still don t work check the fuse If the fuse is good try cleaning the battery terminals If the battery cable ends are corroded they can prevent the flow of current If the engine still won t start after checking compression fuel flow and current to the ignition then check the spark plugs Remove a plug and check the gap
38. plex than drum brake e It requires lot of effort at maintenance front like brake fluid bleeding change of brake pads etc compare to drum brake Lecture Hour 4 Brake Layout 25 Fh sjj Dfi l ELAN DHUA FR Ww HEEL CLA T FITEG PTR Pel ae VALVE fe ft Sep LENN S EU 14 MASTER CTL TETRA FRL Wheel parts A wheel is a circular object which with an axle allows low friction in motion by rolling A wheel is made up of the rim and spokes or disc plate The standard size of wheels for two wheelers is 17 inch Wheels should be aligned properly because it directly influences driving Lecture Hour 5 Wheels Wheels must be strong enough to support the vehicle and withstand the forces caused by normal operation At the same time they must be as light as possible to help keep un sprung weight to a minimum Wheels can be made from cast aluminium alloy or magnesium alloy Alloy wheels are popular because of their appearance and because they are lighter than similar steel wheels Aluminium is a better conductor of heat so alloy wheels can dissipate heat from brakes and tyres more effectively than steel ones Most wheels have ventilation holes in the flange so air can circulate to the brakes Most passenger car wheels are of well or drop centre design This design allows for tyre removal and fitting The removal and fitting of tyres should be carried out according to manufactures instructions Types of
39. re Hour 1 Introduction to Moped Scooter and Motorcycle 4 WAM ae a aaa Pig 1 Jia Wed Mda Farra L luf beep 1 Har rede pr pep 4 Lege taar 5 olka Hmm Ree PDU m 7 licdr ag came E Tudor gt Tul nk dla c Me LI Deda E Tre IE Femi Fak 4 Frei a ES Paw oks olaa ika 7 Foki Are kiki da 6 kr combs iial pniaki I figan dir iter zla JE Mul H Faar hna EF jk Rage he Fr hirri i rskr genres 1 bahani ger ob Erere H Kat piy thle he A leo abel ieii 27 LE lat linii rel mt lot Feii z Pelni ery pair Fri tet LA font Ta Pag Qeztral a ed gl ertia hrf sais UR bear dike j ke Ligi bikr Care Frat sigur hing irii 28 MOTORCYCLE passenger dual gas restraint handle seat tank handlebar dashboard headlight fn 4 y 4 i y 4 lt U front mudguard tail light telescopic shock rear mudguard _ absorber spring suspension oc disk brake aluminium rim exhaust main frame pipe stand WWW INFOVISUAl INFO Lecture Hour 2 Technical specification of MOPED TECHNICAL SPECIFICATIONS OF TVS XL Engine Type 2 stroke single cylinder Bore x Stroke 46 x 42 mm Displacement cc 69 9 2 61 Kw 3 5 Bhp 5000 Max power rpm Torque Nm 5 0 3750 rpm Drive Clutch Centrifugal wet type Primary Drive Single speed gear box Secondary Drive Roller chain drive Electricals Fly wheel magneto 12V 50W Electronic
40. re piston port meaning that the piston movement past the port controls the incoming air timing The piston port engine doesn t do a very good job of keeping the airflow to stay in the engine The air can simply travel back out of the engine The most popular intake air induction is the reed port engine It 6 uses reed petals to allow the intake air in the engine and traps it there The tension of the reed petals can change with the use of different petals and can provide some power improvement at certain rom ranges A rotary valve engine has the best intake air control Lecture Hour 6 Constant Vaccum Carburetor F TULIM Z DIAPHRAGM CHAMBER r En ES NE a AF PIN F ZELL aa 7 MAIN BORE ATMOS SPHERIC F maai a J RH Eie AT biel M 1 4 AIR FLOW 4 yA G 4 THROTTLE VALVE A vacuum actuated valve for a constant vacuum type carburetor is formed with a first guide hole a jet needle engaging step portion and a jet needle insertion hole therein A spring seat has an outer cylindrical portion in an upper portion thereof and an inner cylindrical portion and a jet needle supporting cylindrical portion therein The outer cylindrical portion of the spring seat is arranged on the outer circumference of a diaphragm plate The jet needle supporting cylindrical portion is inserted within a first guide hole A lower end of a vacuum actuated valve return spring engages with a spring seating flange of the spring seat A flange portion of
41. t or wrong type of Transmission fluid used Lecture Hour 9 Two Wheeler Maintenance and Servicing It is often seen that people are seeking newer vehicles that would give them ultimate comfortable ride and would serve the purposes needed It is quite a common sight that a significant number of two wheeler owners neglect proper maintenance of their vehicles resulting in their longevity getting affected No wonder almost all the two wheeler companies in India have come up with their automobile service centers throughout the country These service centers play a vital role in the effective servicing of your favorite two wheeler With proper maintenance of your vehicle you can certainly reduce the servicing cost that you might have to incur at a later stage Following through some of the simple to follow maintenace tips one can ensure better and optimal and fuel efficient performance of the two wheeler It has been seen that with the relevant maintenance tips for the two wheelers you can significantly retain their level of performance By following the various maintenance tips provided by automobileindia com you will be able to increase the efficiency of the vehicles To keep your vehicles in a very good shape it is quite necessary that you regularly keep changing the oil It is also important that you keep notice of the condition of the tires working of the batteries and also the functioning of the electrical system of the automobile A healthy elec
42. time Lecture Hour 7 SUSPENSION SYSTEM Introduction A Motorcycle Suspension System consists of a spring coupled to a viscous damping element a piston in a cylinder filled with oil The piston smooths out vibrations induced by the vehicle while moving as it moves through the oil The flow of oil through the piston is regulated by an adjustable elastic deformable flap called a shim trail wheelbase a offset Motorcycle Suspension e Front Suspension The predominant type of front suspension is the suspension fork The bottom part of the fork is fitted over the tubes that 18 connect the fork to the frame When the vehicle hits a bump the spring gets compressed and the piston forces fluid through the orifice e Rear Suspension Most of the time the rear suspension are used as a shock absorber Functions of Motorcycle Suspension The main functions of the motorcycle suspensions are e To insulate both the rider and the bulk of the machine from road shocks It makes a much safer and comfortable ride and is important for proper mechanical reliability and longevity e To keep the wheels in the closest possible contact with the ground and gives control of the vehicle to the rider e The front suspension helps to guides the front wheel to steer to spring to dampen and to provide support under braking Materials used for making Suspensions The materials most commonly used for making suspensions are e Steel
43. ting rod or piston This can be caused by a variety of problems including valve seizure rocker arm seizure cylinder or piston seizure connecting rod seizure transmission gear or bearing seizure and camshaft seizure When checking for engine rotation also check the clutch If the clutch is worn and slipping badly it will appear that the engine is turning when it is actually locked up Unusual noises can be caused by a variety of problems For example a heavy clunking sound coming from the bottom end could indicate a loose connecting rod Lack of compression is usually a problem caused by the pistons rings valves or cylinder bore If the bottom end prats seem to be working correctly then the problem is combustion related After checking the basics then we move on to the essentials Fuel compression and ignition Checking The Fuel Supply 34 When troubleshooting this problem check for fuel in the tank fuel flow to the carburetor and fuel flow from the car to the engine Restricted or no fuel flow can be caused by clogged fuel petcock fuel tank air vent obstruction clogged fuel line or clogged float valve Trace the system to check for blockage Start with the fuel tank air vent then the fuel petcock fuel line and float valve Fuel restriction to the engine is indicated by a dry spark plug Fuel flow from the carb to the engine can be interrupted by air leaks between the carburetor and the inlet manifold If you ha
44. trical system and a well charged battery ensures quick start of your vehicle without any trouble There are a number of measures that you can take to ascertain the longevity of your automobile While driving your vehicle if some strange sound occurs then that would require immediate attention Problems could be with the wheels fan belt engine and various other internal parts of the vehicle Some of the popular maintenace tips associated with the care of two wheelers are as follows e Two Wheeler Maintenance and Servicing It is often seen that people are seeking newer vehicles that would give them ultimate comfortable ride and would serve the purposes needed It is quite a common sight that a significant number of two wheeler owners neglect proper maintenance of their vehicles resulting in their longevity getting affected No wonder almost all the two wheeler companies in India have come up with their automobile service centers throughout the country These service centers play a vital role in the effective servicing of your favorite two wheeler 40 With proper maintenance of your vehicle you can certainly reduce the servicing cost that you might have to incur at a later stage Following through some of the simple to follow maintenace tips one can ensure better and optimal and fuel efficient performance of the two wheeler It has been seen that with the relevant maintenance tips for the two wheelers you can significantly retain their le
45. ts Three basic systems are in use the cross flow the loop and the uniflow All modern slow speed diesel engines now use the uniflow scavenging system 5 with a cylinder head exhaust valve CROSS FLOW SCAVENGING Fig a In cross scavenging the incoming air is directed upwards pushing the exhaust gases before it The exhaust gases then travel down and out of the exhaust ports Figure above illustrates the process LOOP FLOW SCAVENGING Fig b In loop scavenging the incoming air passes over the piston crown then rises towards the cylinder head The exhaust gases are forced before the air passing down and out of exhaust ports located just above the inlet ports The process is shown in Figure below UNIFLOW SCAVENGING Fig c With uniflow scavenging the incoming air enters at the lower end of the cylinder and leaves at the top The outlet at the top of the cylinder may be ports or a large valve The process is shown here Lecture Hour 5 Rotary Valve Engine A rotary valve engine is always a two stroke engine Most rotary valve engines are rotax engines Although other rotary engines such as suzuki and kawasaki have been made iyare 1 1 iaei este bogie RA kre proriurw anal dese whan he peer oe Rotax engines are used in snowmobiles jet skis and motorcycles and aircraft engines A rotary valve refers to the intake of a two stroke engine There are three types of intake designs for two stroke engines Simplistic two strokes a
46. uces a spark and ignites the air fuel mixture Such combustion is called constant volume combustion C V C Compression ignition engine In compression ignition engines air is compressed in to the engine cylinder Due to this the temperature of the compressed air rises to 700 900 C At this stage diesel is sprayed in to the cylinder in fine particles Due to a very high temperature the fuel gets ignited This type of combustion is called constant pressure combustion CP C because the pressure inside the cylinder is almost constant when combustion is taking 1 place 4 Based on working cycle 1 Four stroke cycle engine When the cycle is completed in two revolutions of the crankshaft it is called four stroke cycle engine 2 Two stroke cycle engine When the cycle is completed in one revolution of the crankshaft it is called two stroke cycle engine CONSTRUCTION OF AN IC ENGINE I C engine converts the reciprocating motion of piston into rotary motion of the crankshaft by means of a connecting rod The piston which reciprocating in the cylinder is very close fit in the cylinder Rings are inserted in the circumferential grooves of the piston to prevent leakage of gases from sides of the piston Usually a cylinder is bored in a cylinder block and a gasket made of copper sheet or asbestos is inserted between the cylinder and the cylinder head to avoid ant leakage The combustion space is provided at the top of the cylinder hea
47. ultiplate Clutch Ihaa hazel miler plate i S ware J WA Spn mT EE p A i Poke 2 3 l aahi gwal a Fig kuli piwie cach Automobiles uses various kinds of clutches such as singleplate or multiplate clutch Each clutch has got its own design construction and working principle Multiplate clutch consists of a number of clutch plates where as singleplate clutch has only one clutch plate As the number of clutch plates are increased the friction surface also increase The increased number of friction surfaces in clutch increases the capacity of the clutch to transmit torque in automobiles The plates are alternately fitted to the engine shaft and gear box shaft They are firmly pressed by strong coil springs and assembled in a dru Each of the alternate plate slides in grooves on the flywheel and the other slides on splines on the pressure plate Therefore each alternate plate has inner and outer splines The multipleate clutches operating condition may be dry or wet When the clutch is operated in an oil bath it is called a wet clutch When the clutch is operated dry it is called dry clutch The wet clutches are generally used in conjunction with the automatic transmission automotives Multiplate clutch works in the same way as the single plate clutch i e by operating the clutch pedal The multiplate clutches are used in heavy commercial vehicles automobiles racing cars and motor cycles for transmitting high torque L
48. uspension Rear Suspension Coil Spring Shock Absorbers Tire Size Front 3 5 x 10 Ceat Secura Rear 3 5 x 10 Ceat Secura Interior e N A Exterior Colour LML Vespa Misty Silver Vespa 150 Midnight Black Vespa 150 Flame Orange Lambretta Red and Cream Dual Tone Vespa PVX Crsytal White and Turquoise Blue Dual tone LML Vespa Select Night Blue and White LML Vespa Alfa Lilac Lecture Hour 4 Technical specification of Motorcycle Passion pro Technical Specifications Engine e Type Air cooled 4 stroke single cylinder OHC e Displacement 97 2 cc 31 e Max Power 5 74 kW 7 8 Ps at 7500 rpm e Max Torque 0 82 Kgf m 8 04 N m at 4500 rpm e Max Speed e Acceleration e Bore x Stroke 50 0 x 49 5 mm e Carburettor Side Draft Variable venturi type with TCIS e Compression Ratio 9 0 1 e Starting Electric start Kick start e Ignition DC Digital CDI with TCIS e Oil Capacity 1 05 litres e Oil Grade SAE 10W 30 SJ Grade JASO MA Lecture Hour 5 YAMAHA MOTOR CYCLE 32 ENGINE Engine type Air cooled 4 stroke SOHC Displacement 153 0cc Bore amp Stroke 58 0 x 57 9mm Compression ratio 9 5 1 Maximum output 14PS 7500 rpm Maximum torque 13 6 N m 6000 rpm Starting method Electric amp Kick Lubrication type Wet Sump Fuel Supply Carburetor Clutch type Wet multiple disc aE a A reduction og 12 857 Transmission type Constant mesh 5 speed L 1st 2 714 2nd 1 789 3rd 1 318 4th
49. utch will tend to keep the engine at or near the torque peak of the engine This results in a fair bit of waste heat but over a broad range of speeds it is much more useful than a direct drive in many applications Lecture Hour 4 CHASSIS The two wheeler chassis consists of the frame suspension wheels and brakes The chassis is what truly sets the overall style of the two wheeler Automotive chassis is the main carriage systems of a vehicle The type determines the gearing configuration flex and the type of modifications that can be accommodated Frame The frame serves as a skeleton upon which parts like gearbox and engine are mounted It can be made of steel aluminum or an alloy It keeps the wheels in line to maintain the handling of the two wheeler Suspension It is a collection of springs and shock absorbers It can be of two types front suspension and rear suspension It insulates both the rider and the bulk of the machine from road shocks and also keeps the wheels in the closest possible contact with the ground and gives control of the vehicle to the rider The front suspension helps to guide the front wheel to steer to spring to dampen and to provide support under braking Wheels A wheel is a circular object which with an axle allows low friction in motion by rolling A wheel is made up of the rim and spokes or disc plate Wheels should be aligned properly because it directly influences driving Two wheeler wheels are gener
50. ve e Fuel tank is empty Switch fuel valve to reserve or fill with fuel mixture e Spark plug is contaminated Clean spark plug e Spark plug is defective Replace spark plug e Ignition cable has worked loose or come off Properly plug spark connector e Too much or too little gas Open throttle about 1 3 e Vehicle put out of operation with fuel valve open Start with throttle wide open e Choke operated with warm engine Remedy as above e Petcock is clogged Have it cleaned by a workshop e Main jet is clogged Clean main jet e Float needle not fixed in its notch Remove float needle and engage it Version Two The engine will not start because There is no ignition spark because e Spark plug is oiled wet or damaged e Spark plug is wet outside e Ignition cable is loose or broken e Short circuit switch jams or leads from engine are damaged e Contact breaker points are oiled up wet or fused e Ignition armature or condenser is damaged Engine is getting no fuel because e No fuel in tank e Fuel valve petcock closed e Strainer in the fuel valve petcock clogged with dirt e Fuel line hose jammed e Jets clogged There is no ignitable mixture because e Fuel air mixture too rich due to excessive priming e Water in carburetor e Wrong fuel air mixture due to loose carburetor Lack of compression because e Piston rings broken 37 Piston and cylinder excessively worn Cy
51. ve a two stroke engine this can be caused by bad bottom end engine seals A wet spark plug indicates a flooded engine A supply of gas that is too much for the engine to burn can be caused by a closed air choke valve a dirty air cleaner a worn or stuck float valve or even improper starting technique To eliminate an improper starting technique when dealing with a flooded engine hold the throttle fully open when cranking over the engine This will allow more air to reach the engine Check to see that the choke is open then check and clean the air filter as needed Make sure the carburetor float isn t stuck open To fix this you have to remove the float bowl and repair or clean it Refer to your factory service manual for exact instructions on removing the float bowl on your make and model Lecture Hour 7 Trouble Shooting continuous Checking For Compression The pistons rings valves spark plugs and cylinder need to form an air tight seal that will allow the air fuel mixture to compress to the point of combustion These parts are checked with a compression gauge Compression has to be within factory specs which you will find in your factory service manual With four stroke engines low compression requires a leakdown test which provides a more accurate indication of the problem area Low compression can be caused by a loose spark plug cylinder heads that are not properly tightened down no valve clearance worn cylinder walls
52. vel of performance By following the various maintenance tips provided by automobileindia com you will be able to increase the efficiency of the vehicles To keep your vehicles in a very good shape it is quite necessary that you regularly keep changing the oil It is also important that you keep notice of the condition of the tires working of the batteries and also the functioning of the electrical system of the automobile A healthy electrical system and a well charged battery ensures quick start of your vehicle without any trouble There are a number of measures that you can take to ascertain the longevity of your automobile While driving your vehicle if some strange sound occurs then that would require immediate attention Problems could be with the wheels fan belt engine and various other internal parts of the vehicle Some of the popular maintenace tips associated with the care of two wheelers are as follows In case of a front brake one should ensure if the free play and brake fluid levels are fine e Rear Brake Pedal should be regularly checked and ensured that it is free of any trouble e In acse of alow tire pressure it should be inflated as per the specifications while in case of more that should be deflated Free movement of tire should also be ensured and in case of any trouble on that accountr the service center or mechanics should be consulted e Odour of fuel will indicate a fuel leakage problem and that should be consulte
53. with auto adjuster Rear Brakes Hydraulic brakes with auto adjuster Lecture Hour 5 MAINTENANCE There s not much to maintain on a day to day basis on most modern 3WMCs but do what you can do including your pre ride checks Your bike has a regular service schedule listed in the owners manual Unless you are an accomplished mechanic we recommend that these services be done by an authorized dealer Keeping your 3WMC clean is a good idea It s astounding how dirt can cover up something that is about to go wrong Check your battery every month Make sure the fluid level is where it should be If it is low top it up with distilled water Always take your tool kit along when you go for a ride You never can tell when it will come in handy Use the tools to go over the bike occasionally and make sure no screws or bolts are loose You should always have your owner s manual with the bike It tells you where the fuse box is in the unlikely chance a fuse blows It tells you how to remove a wheel should you have the misfortune of a flat tire Flat tires are pretty rare occurrences on 3WMCs but they can happen In this case you can either get on the phone to the dealer or fix it yourself If you want to know how to do it we recommend you practice at home rather than have your first shot at fixing a flat alongside a deserted road in the middle of the night Lecture Hour 6 Trouble Shooting 1 If the engine doesn t start Is t
54. ype Forced Air Cooled Displacement 145 45 cc 42 Max Power 7 bhp 5 15 kW 5000 rpm Max Torque 12 1 Nm 3500 rpm Ignition Type CDI Transmission Type 4 forward and one reverse Clutch Type Wet multidisc type Electrical System System 12V AC DC Head Light 35 35W Horn 12 VAC Chassis Chassis Type Monocoque Maximum Payload 333 kg Suspension Front Helical spring and hydraulic shock absorber with antidive Suspension link Rear Independent suspension with spring and hydraulic shock Suspension absorber Tyres Front Tyre Size 4 00 8 4PR Rear Tyre Size 4 00 8 4PR 2 Nos Brakes Front Brakes Drum Hydraulic Rear Brakes Drum Hydraulic Lecture Hour 3 Technical Specification of Pick up Van FORD SUPER DUTY PICKUP Specifications Fuel Capacity Drive Type Available Engines Horsepower 43 35 gallons 6 2L V8 gas engine 26 gallons 6 7L Power Stroke Turbo Die and 156 wheelbases 37 5 gallons 6 7L Power Stroke Turbo D 172 wheelbases 4x2 4x4 6 2L V8 Gas FFV 6 7L Power Stroke V8 Turbo Diesel 385 5500 rmp 6 2L V8 under 10K GVW 6 2L V8 over 10K GVWR 400 2800 rpm 6 7L Power Stroke Tur Torque Transmission Wheelbase Maximum Conventional Towing Maximum Payload Maximum GVWR Warranty 405 4500 rpm 6 2L V8 under 10K GVW 6 2L V8 over 10K GVWR 800 1600 rpm 6 7L Power Stroke Tur TorqShift 6 speed SelectShift Automatic 137 0 Regular Cab 141 8 SWB SuperCab

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