iti 15 April 2025
Mechanic Motor Cycle

ITI Mechanic Motor Cycle Trade Syllabus

The ITI Mechanic Motor Cycle trade is a one-year vocational training program under the Craftsman Training Scheme (CTS), governed by the National Council for Vocational Training (NCVT). This course equips trainees with skills in diagnosing, servicing, repairing, and maintaining motorcycles, including two-stroke and four-stroke engines, transmission systems, braking systems, and electrical components. The syllabus integrates theoretical knowledge, practical skills in motorcycle repair, and employability skills to prepare students for roles such as motorcycle mechanics, service technicians, or spare parts dealers in automotive workshops, service centers, or motorcycle dealerships, or as self-employed repair shop owners.

Course Overview

  • Duration: 1 year (2 semesters, each 6 months)
  • NSQF Level: Level 4
  • Eligibility: Minimum 10th grade pass (or equivalent)
  • Objective: To train individuals in ensuring the optimal performance, safety, and reliability of motorcycles through maintenance and repair.

Detailed Syllabus Breakdown 

1. Trade Theory (Theoretical Knowledge)

Covers principles of motorcycle systems, repair techniques, and workshop management.

  • Semester 1
    • Introduction to Motorcycle Mechanics
      • Overview: types of motorcycles (scooters, bikes, mopeds), their applications.
      • Industry scope: roles in service centers, dealerships, repair shops.
      • Safety: PPE (gloves, goggles, boots), workshop hazards, safe lifting techniques.
    • Basic Mechanics
      • Concepts: force, torque, friction, levers in motorcycle systems.
      • Components: nuts, bolts, bearings, gaskets, seals in bikes.
      • Materials: steel, aluminum, rubber used in motorcycle parts.
    • Two-Stroke and Four-Stroke Engines
      • Principles: combustion cycles, valve timing, carburetion, fuel injection.
      • Components: piston, crankshaft, camshaft, spark plug, exhaust system.
      • Operation: differences between 2-stroke and 4-stroke engines, efficiency.
    • Fuel Systems
      • Types: carburetors, fuel injectors, fuel pumps, air filters.
      • Operation: fuel-air mixture, throttle control, choke systems.
      • Maintenance: cleaning carburetors, replacing filters, checking fuel lines.
    • Electrical Systems (Basic)
      • Components: battery, ignition coil, spark plug, wiring harness, lights.
      • Principles: DC circuits, charging systems, grounding techniques.
      • Safety: handling batteries, avoiding short circuits, insulation checks.
    • Tools and Measuring Instruments
      • Hand tools: spanners, screwdrivers, pliers, torque wrenches.
      • Diagnostic: multimeters, feeler gauges, compression testers.
      • Precision: measuring clearances (±0.01 mm), torque settings.
    • Workshop Practices
      • Operations: filing, drilling, tapping, tightening fasteners.
      • Techniques: dismantling, assembling engine components.
      • Documentation: service logs, spare parts lists, job cards.
  • Semester 2
    • Transmission Systems
      • Types: chain drive, belt drive, manual and automatic clutches.
      • Components: gears, sprockets, clutch plates, drive chains.
      • Maintenance: adjusting chain tension, lubricating sprockets, replacing clutches.
    • Braking Systems
      • Types: drum brakes, disc brakes, hydraulic and mechanical systems.
      • Components: brake pads, rotors, cables, brake fluid reservoirs.
      • Maintenance: bleeding brakes, replacing pads, adjusting cables.
    • Suspension and Steering Systems
      • Types: telescopic forks, mono-shock, swing arms.
      • Components: shock absorbers, bearings, steering head, forks.
      • Maintenance: greasing bearings, adjusting dampers, checking alignment.
    • Wheels and Tyres
      • Types: spoke wheels, alloy wheels, tubeless and tube tyres.
      • Operation: tyre pressure, tread patterns, balancing techniques.
      • Maintenance: patching punctures, replacing tyres, aligning wheels.
    • Advanced Electrical Systems
      • Components: CDI units, regulators, starter motors, horn, indicators.
      • Systems: electronic ignition, fuel injection control, wiring diagnostics.
      • Maintenance: testing circuits, replacing relays, troubleshooting faults.
    • Troubleshooting and Diagnostics
      • Methods: fault identification, symptom analysis (noise, vibration, power loss).
      • Tools: diagnostic charts, OBD scanners, compression testers.
      • Solutions: tuning engines, recalibrating fuel systems, fixing electrical faults.
    • Preventive Maintenance
      • Schedules: daily, monthly checks for engines, brakes, tyres.
      • Techniques: oil changes, chain lubrication, spark plug cleaning.
      • Records: logging service intervals, predicting part replacements.
    • Workshop Management
      • Practices: inventory control, customer interaction, billing systems.
      • Compliance: pollution norms (PUC), road safety regulations.
      • Documentation: warranty records, service agreements, compliance certificates.

2. Trade Practical (Hands-On Skills)

Focuses on practical tasks in motorcycle repair workshops.

  • Semester 1
    • Safety Practices
      • Using PPE: wearing gloves, goggles in workshops.
      • Procedures: handling fuel, lifting bikes safely, fire safety drills.
      • Checks: ensuring stable bike stands, spill cleanup.
    • Basic Engine Work
      • Dismantling: removing pistons, valves from mock 2-stroke/4-stroke engines.
      • Assembling: fitting gaskets, tightening bolts to torque specs.
      • Testing: checking valve clearance, crank rotation in labs.
    • Fuel System Maintenance
      • Servicing: cleaning carburetors, replacing air filters in mock setups.
      • Adjusting: tuning fuel-air mixture, setting choke valves.
      • Testing: verifying fuel flow, throttle response in labs.
    • Electrical System Practice
      • Wiring: connecting battery, lights in mock circuits.
      • Testing: checking voltage, spark plug firing with multimeters.
      • Repairing: replacing bulbs, soldering wires in labs.
    • Workshop Operations
      • Performing: tightening fasteners, filing rough edges in mock setups.
      • Measuring: checking piston clearance, bolt torque in labs.
      • Documenting: preparing job cards, part lists for repairs.
    • Project Work
      • Servicing an engine: dismantling, cleaning, reassembling, testing.
      • Report: documenting faults fixed, tools used, outcomes.
  • Semester 2
    • Transmission System Repair
      • Servicing: adjusting chain tension, greasing sprockets in mock bikes.
      • Repairing: replacing clutch plates, aligning gears in labs.
      • Testing: ensuring smooth gear shifts, drive efficiency.
    • Braking System Maintenance
      • Servicing: inspecting brake pads, rotors in mock setups.
      • Repairing: bleeding hydraulic brakes, replacing cables in labs.
      • Testing: verifying stopping power, pedal feel in mock bikes.
    • Suspension and Steering Practice
      • Servicing: greasing steering bearings, checking forks in mock setups.
      • Adjusting: tuning shock absorbers, aligning handlebars in labs.
      • Testing: ensuring stability, smooth steering in mock rides.
    • Wheel and Tyre Maintenance
      • Performing: patching tubes, mounting tyres in mock wheels.
      • Balancing: aligning wheels, checking tyre pressure in labs.
      • Testing: verifying ride comfort, grip in mock setups.
    • Advanced Electrical Repair
      • Diagnosing: testing CDI, starter motors in mock circuits.
      • Repairing: replacing regulators, rewiring harnesses in labs.
      • Testing: ensuring lights, horn, ignition functionality.
    • Troubleshooting Practice
      • Diagnosing: identifying misfires, brake fade in mock bikes.
      • Repairing: tuning carburetors, fixing wiring faults in labs.
      • Testing: verifying performance post-repair in mock setups.
    • Project Work
      • Restoring a motorcycle: full service, repair, testing in labs.
      • Portfolio: presenting logs, photos, performance data.

3. Workshop Calculation and Science

Supports motorcycle repair with relevant concepts.

  • Semester 1: Arithmetic (ratios, tolerances), physics (force, torque).
  • Semester 2: Algebra (gear ratios, fuel efficiency), thermodynamics (combustion).

4. Engineering Drawing

Focuses on technical drafting for motorcycle systems.

  • Semester 1: Sketching engine parts, carburetors, orthographic views.
  • Semester 2: Drawing transmission layouts, brake systems, wiring diagrams.

5. Employability Skills

Enhances job readiness and soft skills.

  • Semester 1: Communication (customer queries), time management, basic IT (billing).
  • Semester 2: Teamwork (with technicians), problem-solving (fault diagnosis), entrepreneurship (shop management).

Assessment and Certification

  • Examinations: Semester-wise (theory + practical).
  • Certification: National Trade Certificate (NTC) from NCVT, recognized nationally.
  • Evaluation: Based on repair accuracy, system performance, safety compliance, and project work.

Career Opportunities

  • Employment: Motorcycle mechanic, service technician, spare parts dealer in workshops, dealerships, or service centers.
  • Self-Employment: Starting a motorcycle repair shop or mobile service unit.
  • Further Studies: Diploma in Automobile Engineering, certifications in advanced diagnostics, or electric vehicle repair.

Note

  • This syllabus aligns with NCVT guidelines and may vary slightly by institution or state.
  • For the latest version, refer to the Directorate General of Training (DGT) or local ITI.

Trade Type

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