GOVERNMENT OF INDIA

MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP

DIRECTORATE GENERAL OF TRAINING

COMPETENCY BASED CURRICULUM

MECHANIC TWO & THREE WHEELER

(Duration: One Year)
Revised in July 2022

CRAFTSMEN TRAINING SCHEME (CTS)

NSQF LEVEL- 3

SECTOR – AUTOMOTIVE
MECHANIC TWO & THREE
WHEELER
(Engineering Trade)

(Revised in July 2022)

Version: 2.0

CRAFTSMEN TRAINING SCHEME (CTS)

NSQF LEVEL - 3

Developed By

Ministry of Skill Development and Entrepreneurship

Directorate General of Training
CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE
EN-81, Sector-V, Salt Lake City,
Kolkata – 700 091
www.cstaricalcutta.gov.in
 CONTENTS

S No. Topics Page No.

1. Course Information 1

2. Training System 2

3. Job Role 6

4. General Information 7

5. Learning Outcome 10

6. Assessment Criteria 11

7. Trade Syllabus 17

8. Annexure I(List of Trade Tools & Equipment) 34

Mechanic Two & Three Wheeler
1. COURSE INFORMATION

During the one-year duration of “Mechanic Two &Three-Wheeler” trade, a candidate is

trained on Professional Skill, Professional Knowledge and Employability Skill related to job role.
In addition to this, a candidate is entrusted to undertake project work, extracurricular activities
and on-the-job training to build up confidence. The broad components covered under
Professional Skill subject are as below: -

During one year duration the trainees learn about safety aspect in general and specific
to the trade, identification of tools & equipment, raw materials used. The trainee will perform
Measuring & marking by using various Measuring & Marking tools. The trainee will be able to
plan and perform basic fastening and fitting operations. Familiarize with basics of electricity,
test and measure the electrical parameter. Practice on maintenance of batteries. Practice
making various welding joints by using Arc and gas welding. The candidate will practice on
dismantling Engine of Two and Three-Wheeler as per given standard procedures. Able to
achieve skill on Overhauling of Cylinder Head, valve train, Piston, connecting rod assembly,
crankshaft, flywheel and mounting flanges, spigot and bearings, camshaft etc. practice
reassembling all parts of engine in correct sequence as per workshop manual. Perform
troubleshooting of Excessive smoke, knocking or abnormal noise etc. Practice servicing of Fuel
Tank and its components, repair and overhaul Steering and suspension system of three
wheelers. The trainee will overhaul brake system, transmission system and LPG/CNG fuel
system of Two and three wheelers. Perform servicing and maintenance.

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2. TRAINING SYSTEM

2.1 GENERAL

The Directorate General of Training (DGT) under Ministry of Skill Development &
Entrepreneurship offers a range of vocational training courses catering to the need of different
sectors of economy/ Labour market. The vocational training programmes are delivered under
the aegis of Directorate General of Training (DGT). Craftsman Training Scheme (CTS) with
variants and Apprenticeship Training Scheme (ATS) are two pioneer schemes of DGT for
strengthening vocational training.

Mechanic Two & Three Wheeler trade under CTS is one of the popular courses delivered
nationwide through a network of ITIs. The course is of one-year duration. It mainly consists of
Domain area and Core area. In the Domain area (Trade Theory & Practical) imparts professional
skills and knowledge, while the core area (Employability Skill) imparts requisite core skills,
knowledge, and life skills. After passing out the training program, the trainee is awarded
National Trade Certificate (NTC) by DGT which is recognized worldwide.

Trainee broadly needs to demonstrate that they are able to:

 Read and interpret technical parameters/ documentation, plan and organize work
processes, identify necessary materials and tools.
 Perform tasks with due consideration to safety rules, accident prevention regulations
and environmental protection stipulations.
 Apply professional knowledge & employability skills while performing the job and
modification & maintenance work.
 Check the components as per workshop manual, identify and rectify errors and
repair/replace components.
 Document the technical parameter related to the task undertaken.

2.2 PROGRESSION PATHWAYS

 Can join industry as Technician and will progress further as Senior Technician, Supervisor
and can rise up to the level of Manager.
 Can become Entrepreneur in the related field.
 Can join the apprenticeship program in different types of industries leading to a
National Apprenticeship Certificate (NAC).
 Self employment
 Can join Advanced Diploma (Vocational) courses under DGT as applicable.

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Mechanic Two & Three Wheeler

2.3 COURSE STRUCTURE

Table below depicts the distribution of training hours across various course elements
during a period of one-year:

Notional Training
S No. Course Element Hours
1st Year
1 Professional Skill (Trade Practical) 840
2 Professional Knowledge (Trade Theory) 240
3 Employability Skills 120

Total 1200

Every year 150 hours of mandatory OJT (On the Job Training) at nearby industry,
wherever not available then group project is mandatory.

4 On the Job Training (OJT)/ Group Project 150

Trainees of one-year or two-year trade can also opt for optional courses of up to 240 hours in
each year for 10th/ 12th class certificate along with ITI certification, or, add on short term
courses

2.4 ASSESSMENT & CERTIFICATION

The trainee will be tested for his skill, knowledge and attitude during the period of course
through formative assessment and at the end of the training programme through summative
assessment as notified by the DGT from time to time.

a) The Continuous Assessment (Internal) during the period of training will be done by
Formative Assessment Method by testing for assessment criteria listed against learning
outcomes. The training institute has to maintain an individual trainee portfolio as detailed in
assessment guideline. The marks of internal assessment will be as per the formative assessment
template provided on www.bharatskills.gov.in

b) The final assessment will be in the form of summative assessment. The All India Trade Test
for awarding NTC will be conducted by Controller of examinations, DGT as per the guidelines as
per the guideline. The pattern and marking structure is being notified by DGT from time to

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Mechanic Two & Three Wheeler

time. The learning outcome and assessment criteria will be the basis for setting question
papers for final assessment. The examiner during final examination will also check the
individual trainee’s profile as detailed in assessment guideline before giving marks for practical
examination.
2.4.1 PASS REGULATION

For the purposes of determining the overall result, weightage of 100% is applied for six months
and one year duration courses and 50% weightage is applied to each examination for two years
courses. The minimum pass percent for Trade Practical and Formative assessment is 60% & for
all other subjects is 33%.

2.4.2 ASSESSMENT GUIDELINE

Appropriate arrangements should be made to ensure that there will be no artificial
barriers to assessment. The nature of special needs should be taken into account while
undertaking the assessment. Due consideration should be given while assessing for teamwork,
avoidance/reduction of scrap/wastage and disposal of scrap/waste as per procedure,
behavioral attitude, sensitivity to the environment and regularity in training. The sensitivity
towards OSHE and self-learning attitude are to be considered while assessing competency.

Assessment will be evidence based comprising some of the following:

 Job carried out in labs/workshop

 Record book/ daily diary
 Answer sheet of assessment
 Viva-voce
 Progress chart
 Attendance and punctuality
 Assignment
 Project work
 Computer based multiple choice question examination
 Practical Examination

Evidences and records of internal (Formative) assessments are to be preserved until

forthcoming examination for audit and verification by examining body. The following marking
pattern to be adopted for formative assessment:

Performance Level Evidence

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Mechanic Two & Three Wheeler

(a) Marks in the range of 60%-75% to be allotted during assessment

For performance in this grade, the candidate  Demonstration of good skill in the use of
should produce work which demonstrates hand tools, machine tools and workshop
attainment of an acceptable standard of equipment.
craftsmanship with occasional guidance, and  60-70% accuracy achieved while
due regard for safety procedures and undertaking different work with those
practices demanded by the component/job.
 A fairly good level of neatness and
consistency in the finish.
 Occasional support in completing the
project/job.

(b) Marks in the range of 75%-90% to be allotted during assessment

For this grade, a candidate should produce  Good skill levels in the use of hand tools,
work which demonstrates attainment of a machine tools and workshop equipment.
reasonable standard of craftsmanship, with  70-80% accuracy achieved while
little guidance, and regard for safety undertaking different work with those
procedures and practices demanded by the component/job.
 A good level of neatness and consistency
in the finish.
 Little support in completing the
project/job.

(c) Marks in the range of more than 90% to be allotted during assessment
For performance in this grade, the candidate,  High skill levels in the use of hand tools,
with minimal or no support in organization machine tools and workshop equipment.
and execution and with due regard for safety  Above 80% accuracy achieved while
procedures and practices, has produced work undertaking different work with those
which demonstrates attainment of a high demanded by the component/job.
standard of craftsmanship.  A high level of neatness and consistency
in the finish.
 Minimal or no support in completing the
project.

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Mechanic Two & Three Wheeler
3. JOB ROLE

Mechanic, Motor Cycle; after successful completion of the above course, the trainee shall be
able to perform the following skills with proper sequence. Repairs, services and overhauls
motor cycles, auto rickshaws, scooters; etc., to keep them roadworthy. Examine motor cycle or
scooter to locate faults by running engine in stationary position or by driving it on road.
Dismantle parts such as engine, ignition system, dynamo forks, shock absorbers, gear box etc.,
as necessary. Grinds valves, sets timings, relines brakes, re-bushes steering mechanism,
replaces worn out parts, assembles gear box clutch etc. Performs other tasks to affect repair,
cleans and sets carburetor, fits driving chain, wheels silencer, kick, gear, clutch and brake levers
and other accessories. Adjusts control cables for brake, clutch and accelerator, sets tappets and
wheel alignment, tightens loose parts and makes necessary fittings and connections. Changes
engine and gear box oil, starts engine and tunes it up. Tests performance of vehicle by driving
on road and makes further adjustments to remove defects noticed if any. Assembles motor
cycle or auto-rickshaws from previously dismantled parts.

Auto Service Technician (two and three wheelers); is responsible for the repairing and routine
servicing and maintenance (including electrical and mechanical aggregates) of two/three-
wheeler vehicles.

Plan and organize assigned work and detect & resolve issues during execution in his own
work area within defined limit. Demonstrate possible solutions and agree tasks within the
team. Communicate with required clarity and understand technical English. Sensitive to
environment, self-learning and productivity.

Reference NCO-2015:
i) 7231.0500 - Mechanic, Motor Cycle
ii) 7231.0501 - Auto Service Technician

Reference NOS:
i) ASC/N9801
ii) ASC/N1420
iii) ASC/N9423
iv) ASC/N9424
v) ASC/N9425
vi) ASC/N9426
vii) ASC/N9427
viii) ASC/N9428
ix) ASC/N9429
x) ASC/N9430
xi) ASC/N9431
xii) ASC/N9432
xiii) ASC/N9433
xiv) ASC/N9434

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Mechanic Two & Three Wheeler
4. GENERAL INFORMATION

Name of the Trade Mechanic Two & Three Wheeler

Trade Code DGT/1068
NCO - 2015 7231.0500, 7231.0501
ASC/N9801, ASC/N1420, ASC/N9423, ASC/N9424, ASC/N9425,
NOS Covered ASC/N9426, ASC/N9427, ASC/N9428, ASC/N9429, ASC/N9430,
ASC/N9431, ASC/N9432, ASC/N9433, ASC/N9434
NSQF Level Level - 3
Duration of Craftsmen
Training One year (1200 hours + 150 hours OJT/Group Project)
Passed 10th class examination with Science and Mathematics or its
Entry Qualification
equivalent.
Minimum Age 14 years as on first day of academic session.
Eligibility for PwD LD, LC, DW, AA, LV, DEAF
Unit Strength (No. Of
20 (There is no separate provision of supernumerary seats)
Student)
Space Norms 100 sq. m (including parking area)
Power Norms 3 KW
Instructors Qualification for
1. Mechanic Two & Three B.Voc /Degree in Automobile/ Mechanical Engineering (with
Wheeler specialization in Automobile) from AICTE/UGC recognized
Engineering College/ university with one-year experience in the
relevant field.
OR
3 years Diploma in Automobile/Mechanical (specialization in
automobile) from AICTE/ recognized board of technical education
or relevant Advanced Diploma (Vocational) from DGT with two
years’ experience in the relevant field.
OR
NTC/NAC passed in the trade of “Mechanic Two & Three Wheeler”
with three years’ experience in the relevant field.

Essential Qualification:
Relevant Regular / RPL variants of National Craft Instructor
Certificate (NCIC) under DGT.
Must possess valid LMV and MCWG Driving License.

NOTE: - Out of two Instructors required for the unit of 2(1+1), one

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Mechanic Two & Three Wheeler

must have Degree/Diploma and other must have NTC/NAC

qualifications. However, both of them must possess NCIC in any
of its variants.
2. Workshop Calculation & B.Voc/Degree in Engineering from AICTE/UGC recognized
Science Engineering College/ university with one-year experience in the
relevant field.
OR
03 years Diploma in Engineering from AICTE / recognized board of
technical education or relevant Advanced Diploma (Vocational)
from DGT with two years’ experience in the relevant field.
OR
NTC/ NAC in any one of the engineering trades with three years’
experience.

Essential Qualification:
Regular / RPL variants of National Craft Instructor Certificate
(NCIC) in relevant trade
OR
Regular / RPL variants NCIC in RoDA or any of its variants under
DGT
3. Engineering Drawing B.Voc/Degree in Engineering from AICTE/UGC recognized
Engineering College/ university with one-year experience in the
relevant field.
OR
03 years Diploma in Engineering from AICTE / recognized board of
technical education or relevant Advanced Diploma (Vocational)
from DGT with two years’ experience in the relevant field.
OR
NTC/ NAC in any one of the Mechanical group (Gr-I) trades
categorized under Engg. Drawing’/ D’man Mechanical / D’man
Civil’ with three years’ experience.

Essential Qualification:
Regular / RPL variants of National Craft Instructor Certificate
(NCIC) in relevant trade
OR
Regular / RPL variants of NCIC in RoDA / D’man (Mech /civil) or any
of its variants under DGT.
4. Employability Skill MBA/ BBA / Any Graduate/ Diploma in any discipline with Two
years’ experience with short term ToT Course in Employability
Skills.
(Must have studied English/ Communication Skills and Basic
Computer at 12th / Diploma level and above)

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OR
Existing Social Studies Instructors in ITIs with short term ToT
Course in Employability Skills.

5. Minimum Age for 21 Years

Instructor
List of Tools and Equipment As per Annexure – I

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Mechanic Two & Three Wheeler
5. LEARNING OUTCOME

Learning outcomes are a reflection of total competencies of a trainee and assessment will
be carried out as per the assessment criteria.

5.1 LEARNING OUTCOMES

1. Comply with environment regulations and housekeeping in the work shop following
safety precautions. (ASC/N9801)
2. Check &Perform precision measurements and marking by using various measures and
marking tools used in automotive work shop practices. (ASC/N1420)
3. Plan and Perform basic fastening and fittings operation by using correct hand tools,
machine tools and equipments. (ASC/N1420)
4. Perform surface finishing operations in the given job. (ASC/N9423)
5. Construct electrical circuits and test its parameters by using electrical measuring
instruments. (ASC/N1420)
6. Perform basic electrical testing in two and three wheelers. (ASC/N1420)
7. Perform battery testing and charging operations. (ASC/N1420)
8. Construct basic electronic circuits and testing. (ASC/N9424)
9. Join Components by using Arc & Gas welding. (ASC/N9425)
10. Inspect the Auto component using nondestructive testing method. (ASC/N1420)
11. Identify the hydraulic and pneumatic components in a vehicle. (ASC/N1420)
12. Check and interpret vehicle specification data and VIN, select & operate various service
station equipment. (ASC/N1420)
13. Carry out the general servicing of two and three wheelers. (ASC/N1420)
14. Carry out Engine overhaul of two/three wheelers. (ASC/N9426)
15. Overhauling of cylinder head assembly. (ASC/N9427)
16. Diagnosis and trouble shoot for excessive smoke, engine overheating and abnormal
noise. (ASC/N1420)
17. Carry out Servicing of fuel tank. (ASC/N1420)
18. Carry out overhauling of steering and suspension system. (ASC/N1420)
19. Overhauling front and rear wheels, brake. (ASC/N1420)
20. Overhaul automatic/manual transmission of two and three wheeler. (ASC/N9428)
21. Overhaul AC generator. (ASC/N9429)
22. Check ignition circuit for proper functioning. (ASC/N1420)
23. Overhaul the LPG/ CNG fuel supply system and check exhaust smoke. (ASC/N9430)
24. Carry out servicing and maintenance of Electric two and three wheeler. (ASC/N9431)
25. Carryout survey of fuel injection system components. (ASC/N9432)
26. Read and apply engineering drawing for different application in the field of work.
27. Demonstrate basic mathematical concept and principles to perform practical
operations. Understand and explain basic science in the field of study.

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Mechanic Two & Three Wheeler
6. ASSESSMENT CRITERIA

LEARNING OUTCOMES ASSESSMENT CRITERIA

1. Comply with environment Identify environmental pollution and contribute to the
regulations and avoidance of instances of environmental pollution
housekeeping in the Carryout maintenance and cleaning of work shop and lifting
workshop (5S / Kaizen) equipment environmentally friendly manner.
following safety Avoid waste and dispose waste as per procedure the working
precautions. (ASC/N9801) environment.
Recognize different components of 5S and apply the same in
the working environment.

2. Check & perform Plan the working principles of measuring instruments and
measuring and marking by special tools required for auto workshop.
using various measuring Select, care and use of measuring instrument.
and marking tools. Select, care and use of measuring instrument.
(ASC/N1420)

3. Plan and perform basic Describe the purpose, use of auto hand tools.
fastening operation by List the safety rules for hand tools.
using correct hand tools, Select the correct tool for the job.
machine tools and Set up the tacked pieces in specific position.
equipments. (ASC/N1420) Joint components by Brazing, Soldering, Riveting as per given
drawing.
Produce components by different operation (Drilling, Reaming,
Taping, Dieing)

4. Perform surface finishing Do surface finishing of the job to meet specifications by

operations in the given job. scraping.
(ASC/N9423) Sharpen the scraping tool by grinding.
Check accuracy/correctness of the job using measuring
instruments.
Do surface finishing of the job to meet specifications by
scraping.

5. Construct electrical circuits Plan and organize the work for basic electrical operations.
and test its parameters by Select the tools, instruments and materials required to do the
using electrical measuring job.
instruments. (ASC/N1420) Comply with safety rules when performing the basic electrical
operations.
Perform electrical wire joints, form electrical circuits and test
basic electrical parameters as per the circuit drawings and
operating procedures.

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Mechanic Two & Three Wheeler

6. Perform basic electrical Plan and organize the work for auto electrical component
testing in two and three testing.
wheelers. (ASC/N1420) Tracing the auto electrical components in a vehicle.
Test continuity and voltage drop in the electrical circuits.
Operate the electrical components in a vehicle and test lamps.

7. Perform battery testing Ascertain and select tools and materials for the job.
and charging operations. Comply with safety rules when performing the following
(ASC/N1420) operations.
Plan and select different methods for charging the battery.
Perform battery testing as per the operating procedure.

8. Construct basic electronic Plan and select different types of basic electronic components
circuits and testing. and measuring instruments.
(ASC/N9424) Construct and test the basic electronic gate circuits and its
components as per the standard procedure.

9. Join components by using Determine the principles, process of different welding process
Arc & Gas welding. applicable in automobile industry.
(ASC/N9425) Demonstrate the edge preparation for butt and fillets welds.
Select the type and size of filler rod and flux/electrode, size of
nozzle and gas pressure/welding current, preheating method
and temperature as per requirement.
Set and tack metals as per drawing.
Deposit the weld maintaining appropriate technique and safety
aspects.
Cool the welded joint by observing appropriate cooling method.
Use post heating, peening etc. as per requirement.
Clean the joint and inspect the weld for its uniformity and
different types of surface defects.

10. Inspect the Auto Classify different vehicle components by its manufacturing
Component using non- processes.
destructive testing Ascertain and select tools and equipment to do NDT test the
methods. (ASC/N1420) given job.
Plan and organize the work for nondestructive testing.
Perform different types of nondestructive tests using
appropriate testing equipment.
Observe safety/ precaution during testing the job.

11. Identify the hydraulic and Comply with safety rules when performing the following

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Mechanic Two & Three Wheeler

pneumatic components in operations.

a vehicle. (ASC/N1420) Locate and identify the hydraulic components in a vehicle.
Locate and identify the pneumatic components in a vehicle.

12. Check & Interpret Vehicle Identify of different type of vehicle

Specification data and VIN. Identify the different vehicle specification data and information
Select & operate various Demonstrate the garage, service station different equipment
Service Station
Equipments. (ASC/N1420)

13. Carry out the general Follow and maintain procedure to achieve a safe working
servicing of two & three environment in line with general servicing of two & three
wheeler. (ASC/N1420) wheeler.
Identify & locate the parts of two & three wheeler.
Comply with safety rules when performing the operation.
Select tools, equipment’s and material required for servicing of
vehicle.
Wash the vehicle with washer with appropriate pressure
required for each parts.
Change and maintain the oil level as required.
Lubricate the components which are necessary.

14. Carry out engine Overhaul Carry out Engine overhaul of two / three wheeler.
of two and three wheelers. Plan and select the correct tools, equipments and material to
(ASC/N9426) carry out the job.
Remove engine from vehicle.
Dismantle the engine as per standard procedure of mfg.
Check the components and compare with standard specification
for its correctness.
Replace the parts by doing necessary adjustments. As per
specification
Reassemble the engine. (Torque requirement, soft / hard joint
knowledge / understanding).
Refill the engine oil. Understanding of different types of
automobile oils.
Check drive chain tension and lubricate it.
Check the performance of electrical system.

15. Overhauling of cylinder Select tools, equipment’s, measuring instruments and material
head assembly. required for servicing of overhauling head assembly.
(ASC/N9427) Comply with safety rules when performing the operation.
Check cylinder head assembly for functioning.

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Mechanic Two & Three Wheeler

Remove dismantle and clean cylinder head assembly.

Measure dimension of all components in accordance with
standard specification by using precision gauges.
Replace/Repair and assemble the components of cylinder head
assembly.
Assemble cylinder head assembly as per mfg. guide line.
Check and adjust tappet clearance as per specification.
Set ignition timing and start engine set for idling.

16. Diagnosis and trouble Select tools, equipment’s, measuring instruments and material
shoot for excessive smoke, required for servicing of cylinder head assembly.
engine overheating and Comply with safety rules when performing the operation.
abnormal noise. Diagnosis and trouble shoot for excessive smoke.
(ASC/N1420) Diagnosis and trouble shoot for engine overheats.
Diagnosis and trouble shoot for engine abnormal noise.

17. Carry out Servicing of fuel Select tools, equipment’s, measuring instruments and material
injection system required for servicing of fuel tank.
components. (ASC/N1420) Plan, organize work and Comply with safety rules when
performing job.
Remove fuel tank and check for leakage and flow.
Remove petrol tap, clean and refit the strainer.
Refit the tank and check for proper functioning.
Check fuel tank cap breathing function.

18. Carry out overhauling of Select tools, equipment’s, and material required for the job.
steering and suspension Plan, organize work and Comply with safety rules when
system. (ASC/N1420) performing job.
Identify the parts of steering and suspension system.
Overhaul steering system.
Overhaul suspension system.
Check shock absorber for proper functioning and replace if
necessary.

19. Overhauling front and rear Select tools, equipment’s, and material required for the job.
wheels, brake. Plan, organize work and Comply with safety rules when
(ASC/N1420) performing job.
Remove front and rear wheel, dismantle and check for truing,
alignment.
Inspect the brake drum, chain sprocket, rubber pad for worn out
and replace if necessary.
Check tire for wear and tube for puncture.
Check and inflate tire for correct pressure as per specification.

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Mechanic Two & Three Wheeler

Check wheel bearing and grease it. ( Understand specific grease

requirement )
Plan, organize work and Comply with safety rules when
performing job.
Checkadjust front and rear brake lever free play as per manual.
Inspect the brake shoe, drum and replace if necessary.
Overhaul hydraulic disc brake.

20. Overhaul Select tools, equipment’s, and material required for the job.
automatic/manual Plan, organize work and Comply with safety rules when
transmission of two and performing job.
three wheeler. Remove, dismantle, check parts, replace worn out parts if
(ASC/N9428) necessary of automatic transmission.
Reassemble automatic transmission and check for proper
functioning. ( Torque requirement , soft / hard joint knowledge /
understanding
Remove and inspect crank shaft, timing sprocket replace if
necessary.
Overhaul kicks start assembly.
Overhaul gear shift mechanism.
Identify and overhaul the oil pump assembly.

21. Overhaul AC generator. Select tools, equipment’s, and material required for the job.
(ASC/N9429) Plan, organize work and Comply with safety rules when
performing job.
Identify the parts of AC Generators. Remove AC Generator,
dismantle, check components, replace if necessary.
Trace the ac /dc circuit in three wheelers.
Measure volt, amp, resistance and leakage in a circuit.
Check pulse generator for proper functioning.

22. Check ignition circuit for Select tools, equipment’s, and material required for the job.
proper functioning. Plan, organize work and Comply with safety rules when
(ASC/N1420) performing job.
Identify the parts of ignition circuits.
Measure resistance in primary and secondary winding replace if
faulty.
Check ignition system components for proper functioning.
Inspect and adjust ignition timing.
Set and check emission as per standard

23. Overhaul the LPG/ CNG Select tools, equipment’s, and material required for the job.
fuel supply system and Plan, organize work and Comply with safety rules when

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Mechanic Two & Three Wheeler

check exhaust smoke. performing job.

(ASC/N9430) Identify the parts of LPG/CNG fuel system in three wheelers.
Service the LPG/CNG kit.
Start the engine tune for slow speed.
Identify the parts of smoke meter/ exhaust gas analyzer.
Check diesel engine smoke with the help of smoke meter.
Check petrol/LPG/CNG engine smoke with the help of gas
analyzer and compare with standard emission level.
Tune the vehicle for recommended emission level.

24. Familiarisation with service Locate the F1 system components

Fuel Injection system. Carryout ECM scan by multi scan tool.
(ASC/N9431)

25. Carry out servicing and Select tools, equipment’s, and material required for the job.
maintenance of Electric Plan, organize work and Comply with safety rules when
two and three wheeler. performing job.
(ASC/N9432) Identify the parts of Electric vehicle to be service and maintain.
Carry out servicing and maintenance of vehicle as per mfg.’s
schedule.

26. Demonstrate basic Solve different mathematical problems

mathematical concept and Explain concept of basic science related to the field of study
principles to perform
practical operations.
Understand and explain
basic science in the field of
study.

27. Read and apply Read & interpret the information on drawings and apply in
engineering drawing for executing practical work.
different application in the Read &analyze the specification to ascertain the material
field of work. requirement, tools and assembly/maintenance parameters.
Encounter drawings with missing/unspecified key information
and make own calculations to fill in missing
dimension/parameters to carry out the work.

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Mechanic Two & Three Wheeler
7. TRADE SYLLABUS

SYLLABUS FOR MECHANIC TWO & THREE WHEELER

Duration: One Year
Professional Skills
Reference Learning Professional Knowledge
Duration (Trade Practical)
Outcome (Trade Theory)
With Indicative Hours
Professional Comply with 1. Demonstration of - Importance of trade
Skill 50Hrs.; environment Machinery used in the Training.
regulations and trade. (09 hrs.) - General discipline in the
Professional housekeeping in the 2. Identification to safety - Institute
Knowledge 10 workshop following equipment and their use - Elementary First Aid.
Hrs. safety precautions. etc. (05 hrs.) - Importance of Mechanic 2
(Mapped NOS: 3. Importance of maintenance & 3 wheelers in Industry
ASC/N9801) and cleanliness of - Safety precautions to be
Workshop. (05 hrs.) followed while in handling
4. Demonstration on safe machineries.
handling and Periodic - Energy conservation
testing of lifting equipment, - Safety disposal of used
and Safety disposal of used engine oil, Electrical safety
engine oil. (10 hrs.) tips.
5. Demonstration with health - Safe handling of Fuel
centre. (05 hrs.) Spillage.
6. Demonstration fire service - Fire extinguishers used for
station to provide demo on different types of fire.
First aid and Fire safety. (05 - Safe disposal of toxic dust,
hrs.) - safe handling and Periodic
7. Perform use of fire testing of lifting equipment
extinguishers. (05 hrs.) - Authorization of Moving &
8. Energy saving Tips of ITI road testing vehicles. (10
electricity Usage. (06 hrs.) Hrs.)
Professional Check & Perform 9. Perform practice using all Hand & Power Tools: -
Skill 84 Hrs.; precision marking aids, like steel rule - Marking scheme, marking
measurements and with spring calipers, material-chalk, Prussian
Professional marking by using dividers, scriber, punches, blue.
Knowledge 20 various measures Chisel etc. (25 hrs.) - Cleaning tools- Scraper,
Hrs. and marking tools 10. Perform layout a work wire brush, Emery paper,
used in automotive piece- for line, circle, arcs - Description, care and use
work shop practices. and circles. (15 hrs.) of Surface plates, steel
(Mapped NOS: 11. Perform to measure a wheel rule, measuring tape, try
ASC/N1420) base of bike & auto with square. Calipers-inside and
measuring tape. (15 hrs.) outside. Dividers, surface
12. Perform to remove wheel gauges, scriber,

17
Mechanic Two & Three Wheeler

lug nuts with use of an air - Punches-prick punch,

impact wrench. (15 hrs.) centre punch, pin punch,
13. Perform Practice on hollow punch, number and
General workshop tools & letter punch.
power tools. (14 hrs.) - Chisel-flat, cross-cut.
Hammer- ball pein, lump,
mallet. Screwdrivers blade
screwdriver, Phillips screw
driver, Ratchet
screwdriver.
- Allen key, bench vice & C
clamps,
- Spanners- ring spanner,
open end spanner & the
combination spanner,
universal adjustable open
end spanner.
- Sockets & accessories,
- Pliers ,Combination pliers,
multi grip, long nose, flat-
nose,
- Air impact wrench, air
ratchet, wrenches- Torque
wrenches, pipe wrenches,
car jet washers Pipe flaring
& cutting tool, pullers
- Gear and bearing. (10 Hrs.)
Systems of measurement,
Description, care & use of
- Micrometers
- Outside and depth
micrometer,
- Micrometer adjustments,
- Vernier calipers, Telescope
gauges
- Dial bore gauges, Dial
indicators, straightedge,
feeler gauge, thread pitch
gauge,
- Vacuum gauge, tire
pressure gauge. (10 Hrs.)
Professional Plan & perform 14. Perform general cleaning, - Fasteners- Study of
Skill 84 Hrs.; basic fastening & checking and use of nut, different types of screws,
fitting operation by bolts, & studs etc. (8 hrs.) nuts, studs & bolts, locking

18
Mechanic Two & Three Wheeler

Professional using correct hand 15. Perform of removal of devices, such as lock nuts,
Knowledge 10 tools, Machine tools stud/bolt from blind hole. (8 cotter, split pins, keys,
Hrs. & equipments. hrs.) circlips, lock rings, lock
(Mapped NOS: 16. Perform cutting tools like washers and locating
ASC/N1420) Hacksaw, file, chisel, where they are used.
Sharpening of Chisels, - Washers& chemical
center punch, safety compounds can be used to
precautions while grinding. help secure these
(8 hrs.) fasteners. Function of
17. Perform hacksawing and Gaskets
filing to given dimensions. - Selection of materials for
(15 hrs.) gaskets and packing, oil
seals.
- Cutting tools:- Study of
different type of cutting
tools like Hacksaw, File-
Definition, parts of a file,
specification, Grade,
shape, different type of cut
and uses.,
- OFF-hand grinding with
sander, bench and
pedestal grinders, safety
precautions while grinding.
- Limits, Fits &tolerances:-
Definition of limits, fits
&tolerances with examples
used in auto components
(10 Hrs.)
18. Perform marking and drilling Drilling machine
clear and Blind Holes, - Description and study of
Sharpening of Twist Drills. Bench type drilling
(10 hrs.) machine, Portable
19. Check safety precautions to electrical Drilling machine,
be observed while using a drill holding devices,
drilling machine. (05 hrs.) - Work Holding devices, Drill
20. Perform tapping a Clear and bits. Taps and Dies: Hand
Blind Hole, Selection of tape Taps and wrenches,
drill Size. Calculation of Tap drill
(10 hrs.) sizes for metric and inch
21. Use of stud-extractor. taps. Different type of Die
Cutting Threads on a Bolt/ and Die stock.
Stud. (10 hrs.) - Screw extractors. Hand
22. Adjustment of two piece Reamers, different Type of

19
Mechanic Two & Three Wheeler

Die, Reaming a hole/ Bush hand reamers, Drill size for

to suit the given pin/ shaft, reaming, Lapping, Lapping
scraping a given machined abrasives and type of Laps.
surface. (10 hrs.) (05 Hrs.)
Professional Construct electrical 23. Perform joining wires using - Ground Connections
Skill 25 Hrs.; circuits and test its soldering Iron. (05 hrs..) - Voltmeter, ammeter,
parameters by using 24. Construction of simple Ohmmeter Mulitmeter,
Professional electrical measuring electrical circuits. (05 hrs.) Conductors & insulators,
Knowledge 03 instrument. 25. Perform measure of Wires, Shielding, Resistor
Hrs. (Mapped NOS: current, voltage and ratings. (03 Hrs.)
ASC/N1420) resistance using digital
multimeter. (05 hrs.)
26. Perform continuity test for
fuses, jumper wires, fusible
links and circuit breakers.
(10 hrs.)
Professional Perform basic 27. Perform series, parallel, - Fuses & circuit breakers,
Skill 25 Hrs.; electrical testing in series parallel circuits using Ballast resistor,
two and three Ohm’s law, (10 hrs..) - Stripping wire insulation,
Professional wheelers. 28. Check electrical circuit with cable colour codes and
Knowledge 05 (Mapped NOS: a test lamp, perform voltage sizes, Resistors in Series
Hrs. ASC/N1420) drop test in circuits using circuits ,
multimeter, measure - Capacitors and its
current flow using applications, Capacitors in
multimeter /ammeter, use seriesand parallel. (05 Hrs.)
of service manual wiring
diagram for
troubleshooting. (15 hrs.)
Professional Perform battery 29. Cleaning and topping up of a - Batteries & cells, Lead acid
Skill 25 Hrs.; testing and charging lead acid battery, testing batteries & Stay
operation. (Mapped battery with hydrometer. Maintenance Free (SMF)
Professional NOS: ASC/N1420) (05 hrs.) batteries,
Knowledge 03 30. Perform connection battery - Thermistors, Thermo
Hrs. to a charger for battery couples,
charging, Inspecting & - Relays, Solenoids, Primary
testing a battery after & Secondary windings,
charging. (10 hrs.) (07 Hrs.)
31. Measure and troubleshoot
the cause(s) of excessive
Key-off battery drain
(parasitic draw) and do
corrective action. Testing of
relay and solenoids and its
circuit. (10 hrs.)

20
Mechanic Two & Three Wheeler

Professional Construct basic 32. Identify and test power and - Basic electronics:
Skill 25 Hrs.; electronic circuits signal connectors for Description of
and testing. continuity. (05 hrs.) Semiconductors,
Professional (Mapped NOS: 33. Identify and test different - Solid state devices- Diodes,
Knowledge 07 ASC/N9424) type of Diodes. (05 hrs.) transistors, Thyristors, Uni
Hrs. 34. Perform regulator /rectifier, Junction Transistors ( UJT),
inspection, and assembling. Metal Oxide Field Effect
(05 hrs.) Transistors (MOSFETs),
35. Check NPN&PNP Transistors - Logic gates-OR, AND &
for its functionality, NOT and Logic gates using
Construct and test simple switches. (07 Hrs.)
logic circuits OR, AND & NOT
Logic gates using as
switches. (10 hrs.)
Professional Join components by 36. Setting of Gas welding - Introduction to welding
Skill 16 Hrs.; using Arc & Gas flames, practice to make a and
welding. (Mapped straight beads and joints - Oxy – Acetylene welding,
Professional NOS: ASC/N9425) Oxy- Acetylene welding. principles, equipment,
Knowledge 04 (16hrs.) welding parameters, edge
Hrs. preparation & fit up and
welding techniques.
(04 Hrs.)
Professional Check & Interpret 37. Identify of different type of - Auto Industry - history,
Skill 25 Hrs.; Vehicle Specification Vehicle. (05 hrs.) leading manufacturers,
data and VIN, Select 38. Demonstrate of vehicle development in
Professional & operate various specification data; automobile industry,
Knowledge 04 Service Station Identification of vehicle trends, new product. Brief
Hrs. Equipments. information Number (VIN). about Ministry of Road
(Mapped NOS: (10 hrs.) transport &Highways,
ASC/N1420) 39. Demonstrate of Garage, - The Automotive Research
Service station equipments. Association of India (ARAI),
(10 hrs.) National Automotive
Testing and R&D
Infrastructure Project
(NATRIP), & Automobile
- Association. Definition: -
Classification of vehicles on
the basis of load as per
central motor vehicle rule,
wheels, final drive, and fuel
used, axles, position of
engine and steering
transmission, body and
load.

21
Mechanic Two & Three Wheeler

- Brief description and uses

of Vehicle hoists (04 Hrs.)
Professional Carry out the 40. Identify the parts &general - Two wheelers and three
Skill 25 Hrs.; general servicing of servicing of Two Wheeler wheelers auto Industry in
two & three and Three wheeler, washing, India
Professional wheelers. (Mapped cleaning, oiling, greasing and - Leading manufacturers,
Knowledge 06 NOS: ASC/N1420) lubricating. (05 hrs.) new product.
Hrs. 41. Dismantle the two wheeler Introduction to Engine:
SI engine, cleaning and - Description of internal &
inspecting the parts, external combustion
checking engine bore, piston engines, Classification of IC
rings, connecting rod, engines, Principle &
bearings, crankshaft. (05 working of 2&4-
hrs.) strokediesel engine
42. Assemble all the parts after Compression ignition
assembling inspect Engine Engine(C.I),
oil level, clutch cable free - Principle of Spark Ignition
play. (08 hrs.) Engine(SI), differentiate
43. Adjust Drive chain tension, between 2-strokeand 4
check performance of stroke, C.I engine and S.I
electrical system. (07 hrs.) Engine,
- Direct injection and
Indirect injection,
- Technical terms used in
engine, Engine
specification.
- Study of various
gauges/instrument on a
dash board of a vehicle-
Speedometer, Tachometer,
Odometer and Fuel gauge,
and Indicators such as
gearshift position. (06 hrs.)
Professional Carryout engine 44. Perform dismantling three - Basic engine components
Skill 25 Hrs.; overhaul of two wheeler engine and Engine cams & Description
wheeler& three inspection of cylinder head, & functions of pistons,
Professional wheelers. (Mapped piston, piston ring, piston rings, connecting
Knowledge 06 NOS: ASC/N9426) connecting rod. (05 hrs.) rod and piston pins and
Hrs. 45. Perform measurement of materials. Used
piston ring gap, the piston recommended clearances
ring to groove clearance, for the rings and its
piston OD, cylinder to piston necessity, precautions
clearance, piston pin OD, while fitting rings, common
piston pin hole ID in an X troubles and remedies of

22
Mechanic Two & Three Wheeler

and Y axis, piston to pin piston.

clearance connecting rod - Description and function of
small end ID, connecting rod Crank shaft, Engine
small end to piston pin bearings.
clearance and compare the - Trouble shooting
measurements with service procedure for low
manual. (10 hrs.) compression, High
46. Perform trouble shooting of compression, Excessive
low compression, High noise, and poor idling. (06
compression, Excessive hrs.)
noise, and poor idling. (10
hrs.)
Professional Overhauling of 47. Identify valves and condition Valves & Valve Trains
Skill 25 Hrs.; cylinder head of valve and seat. Inspection - Function of Engine Valves,
assembly. (Mapped of rocker arm and rocker different types, materials,
Professional NOS: ASC/N9427) arm shaft, camshaft, valve Type of valve operating
Knowledge 06 spring, valve guide, valve mechanism, Importance of
Hrs. guide replacement, valve Valve seats, Valve-timing
seat inspection and setting.
replacing. (05 hrs.) - Description of Camshafts &
48. Perform cylinder head drives, importance of Cam
assembly. (05hrs.) lobes, Timing belts
49. Perform inspection of valve &chains.
clearance and Ignition - Trouble shooting
timing and setting. (05 hrs.) procedure for Excessive
50. Perform trouble shooting of smoke, overheating,
Excessive smoke, knocking or abnormal
overheating, knocking or noise. Troubleshooting
abnormal noise. procedure for cam chain
Troubleshooting of cam noise, and cam chain slack
chain noise and cam chain excessively. (06 hrs.)
slack excessively. (10 hrs.)
Professional Diagnose and 51. Perform checking the Intake & exhaust systems
Skill 28 Hrs.; troubleshoot for throttle cable for - Carbureted systems,
excessive smoke, deterioration, damage or - Principle of Carburetor,
Professional engine overheating kinks, measure the throttle type of carburetor working
Knowledge 10 and abnormal noise. grip free play, and of constant velocity type
Hrs. (Mapped NOS: adjustments. Check the carburetor,
ASC/N1420) carburetor idle speed and - Carburetor operation-
adjust as per manual. (05 Carburetion, carburetor
hrs.) systems,
52. Perform compression test. - Metering jets,
Practice on throttle valve Accelerating, Carburetor
disassembly, check the barrels, Carburetor filter

23
Mechanic Two & Three Wheeler

throttle valve and jet needle Diesel fuel Injection

surfaces for presence of dirt, system, Tanks & lines, Fuel
scratches or wear and lines. Idle speed circuit,
assemble the throttle valve. slow speed circuit, high
(06 hrs.) speed circuit, air cleaners,
53. Perform removal of Intake manifolds.
carburetor, float, float valve, Importance of Cooling
jet clean, inspect and adjust systems & Lubrication
the flat level as per manual system. Cooling system and
and assemble the lubrication system
carburetor. (10 hrs.) overview.
54. Adjust the throttle grip free - Function of engine oil,
play and carburetor as per Grades of oil, Lubrication
manual. (02 hrs.) points.
55. Perform removing and - Trouble shooting
cleaning of air cleaner, procedure for Oil level too
Checking of Engine oil level, low and Oil contamination.
oil filter screen cleaning. - Liquid cooling system
Inspection of fuel lines, description and its working
Spark plug. (05 hrs.) - Pressure oil system
description and working.
(10 hrs.)
Professional Carry out servicing 56. Perform removal of fuel Gasoline Fuel Systems:
Skill 25 Hrs; of fuel tank. tank; check that fuel flow - Gasoline fuel
(Mapped NOS: freely from the petrol tap. characteristics.
Professional ASC/N1420) (05 hrs) - Controlling fuel burn,
Knowledge 05 57. Perform removal of petrol Stoichiometric ratio (air-
Hrs. tap and clean the strainer fuel ratio), Air density, Fuel
and assemble. (05 hrs) supply system, Pressure &
58. Diagnose - causes and vacuum.
remedy for engine not - Trouble shooting
starting, high fuel procedure for Engine
consumption, Practice on cranks but would not start,
engine tune. (15 hrs..) Lean mixture, Engine idles
roughly, stalls or turns
poorly, and Rich mixture.
(05 hrs.)
Professional Carryout 59. Identify steering system - Introduction to steering
Skill 50 Hrs.; overhauling of components in two and Principles of steering:
steering and three wheelers. (05 hrs.) Description of different
Professional suspension system. 60. Practice on handle bar types of steering & handle,
Knowledge 10 (Mapped NOS: removal, inspection and fork mounted over races.
Hrs. ASC/N1420) assembling of handlebar. - Description, construction
(05 hrs.) and function of steering

24
Mechanic Two & Three Wheeler

61. Perform removal of front stem.

fork, inspection of front fork - Troubleshooting Procedure
spring, fork tube, piston, for Hard steering Steers to
slider and assembling of one side or does not track
front fork. (5hrs) strain, front wheel
62. Practice on steering stem wobbling, Soft suspension,
removal, steering stem Hard suspension, Front
adjustment. (05 hrs.) suspension noise. (05 hrs.)
63. Inspect condition of fork and
adjust rake of front fork,
dismantle trailing link, adjust
and service of heavy duty
thrust races. (05 hrs..)
64. Identify suspension system Suspension Systems
components in two and - Principles of suspension,
three wheelers. (05 hrs.) Suspension force,
65. Practice on rear shock Description, location,
absorber removal, suspension-description,
inspection of shock absorber construction and working
spring and assembling of principle of telescopic front
shock absorber. (05 hrs.) suspension, suspension oil,
66. Perform removal of swing oil seal installation,
arm, inspection of pivot Shock absorber types
bolt, swing arm. (10 hrs.) - Hydraulic shock absorbers,
67. Inspect condition of shock Gas-pressurized shock
absorbers. Servicing of absorbers, Load-adjustable
suspension, changing bush. shock absorbers,
(05 hrs.) - Manual adjustable rate
shock absorbers, Electronic
adjustable-rate shock
absorbers, Automatic load-
adjustable shock
absorbers. (05 hrs.)
Professional Overhauling front 68. Perform removal of front Wheels &Tyres
Skill 72 Hrs.; and rare wheels, wheel from vehicle, - Function of wheel and
brake. (Mapped inspection of front wheel construction, Wheel types-
Professional NOS: ASC/N1420) axle run-out, front wheel spoke, cast wheel& sizes,
Knowledge 14 bearing inspection, front Wheel balancing, Rim sizes
Hrs. wheel rim run-out, brake &designations, Tyre
drum inspection, and function and structure, size
assembling of front wheel. and designation, Radial ply
(10 hrs.) tyres, Tubeless tyre, Center
69. Practice on removing rear of gravity, Relation
wheel from vehicle, between tyre pressure and

25
Mechanic Two & Three Wheeler

inspection of rear wheel axle life, Tube size, TUFFUP

run-out, rear wheel bearing tube. Aspect ratio of tyre,
inspection, rear wheel rim - Puncture procedure,
run-out, brake drum Repair of TUFFUP tube.
inspection, driven sprocket Tyre construction
inspection, driven sprocket - Types of tyre construction,
removal, and assembling of Tyre materials, Tyre sizes
rear wheel, driven sprocket &designations, Tyre
installation. Check the information, Tyre tread
chains lack and adjust as per designs, Effects of air
manual. (10 hrs.) pressure and uneven wear
70. Dismantle tyres and tubes pattern.
checking puncture. - Descriptions Tire wear
Assembling inflating to Patterns and causes,
correct pressure. Checking & Nitrogen vs atmospheric
adjusting tire pressure by air in tyres. (07 hrs.)
use of air or by Nitrogen
Wheel truing, alignment. (10
hrs.)
71. Analyze tyre wear patterns.
Checking the wheel bearings
and greasing. (07 hrs.)
72. Perform following practical Braking Systems
on Two and three wheelers.- - Braking fundamentals
Measure the front brake Principles of braking,
lever free play and adjust as description, construction
per manual, Measure the and operation of Drum &
rear brake pedal free play disc brakes, advantage
and adjust as per manual. over drum brake,
(10 hrs.) - Description and working
73. Perform Servicing of brake principle of master
system, cleaning, checking, cylinder, Hydraulic
greasing and assembling. pressure & force, Brake
(10 hrs.) fade
74. Inspect the shoes and - Braking system
wheel drums, changing of components- Brake
brake lining. Repairing and pedal/lever , Brake fluid
maintenance of hydraulic hose, Brake fluid,
disc brake used in - Bleeding, Applying brakes,
Motorcycles. (15 hrs.) Brake force, Brake light
switch
- Disc brakes & components
-Disc brake system, Disc
brake operation, Disc

26
Mechanic Two & Three Wheeler

brake rotors, Disc brake

pads, Disc brake calipers,
Brake friction materials,
- Comparison of Drum brake
and Disc brake. ABS Drum
brakes & components. (07
hrs.)
Professional Overhaul 75. Adjust clutch lever free play Clutches & Transmission:-
Skill 50 Hrs.; automatic/manual and adjust as per manual, - Clutch principles, Wet &
transmission of two removing clutch assembly dry clutches Single plate
Professional and three wheelers. from Two-wheeler and clutches, Multi-plate
Knowledge 10 (Mapped NOS: three wheeler cleaning and clutches, Operating
Hrs. ASC/N9428) inspecting parts. (05 hrs.) mechanisms, Description
76. Replace defective parts. of cam chain mechanism.
Fitting clutch assembly. (05 Automatic clutch
hrs.) - Gearbox layout &
77. Inspect and repair work of operation Gearbox layouts,
Automatic clutch and description of gear shift
automatic transmission used mechanism, gear ratio,
in two wheeler and three Gearbox operation, Gear
wheeler. (10 hrs.) drive position – Neutral,
78. Practice on removal of 1st to 5thposition.
crankshaft, inspection of - Trouble shooting
crank shaft, timing sprocket procedure for Clutch slip
replacement and when accelerating, clutch
installation, (05 hrs.) will not disengage, motor
79. Practice on kick starter cycle creeps with clutch
disassembly, inspection and disengaged,
assembly. (05 hrs.) - Excessive lever pressure,
80. Perform disassembly of clutch lever pressure,
transmission, inspection of clutch operation feels
main shaft, counter shaft, rough, Hard to shift,
gearshift drum, shift fork, Gearshift pedal does not
guide pin and gears and return, and Transmission
assembly of transmission. jumps out of gears.
(10 hrs.) - Automatic transmission
81. Removal of oil pump and used in two wheeler and
inspection and assembly three wheeler. (10 hrs.)
of oil pump. (05 hrs.)
82. Gearshift linkage
disassembly, inspection
and assembly of gearshift
linkage. (05 hrs.)
Professional Overhaul AC 83. Practice on A.C. Generator Auto electrical

27
Mechanic Two & Three Wheeler

Skill 50 Hrs.; generator. (Mapped removal, inspection and - Thermistor, Description

NOS: ASC/N9429) installation. (05 hrs.) and function of ignition
Professional 84. Perform removal of cam switch, alternator,
Knowledge 11 chain tensioner, Regulator/rectifier, Ignition
Hrs. inspection of tensioner principles, Ignition
spring and pushrod, components,
installation. (10 hrs.) - Battery power source,
85. Trace the A.C /D.C Ignition coil, DC/ACCDI, TCI
electrical circuit in a two Contact breaker, capacitor
wheeler and three /condenser, Distributors,
wheeler. (05 hrs.) Distributor types,
86. Perform measurement of - High-tension leads, Spark
Resistance, DC voltage plugs, Spark plug
measurement, DC Current components, Principal of
measurement, pulse electronic ignition,
generator,(5hrs.) advantage of electronic
87. Inspect leakage current, ignition.
measurement of charging - Starter motor, Fuse,
voltage. (05 hrs.) throttle position switch,
88. Practice on headlight source coil & pulser coil
removal, headlight bulb Power relay, Silicon
replacement and rectifier,
installation. (05 hrs.) - Description of Charging
89. Practice on removal of system, starting system,
speedometer, indicator Lighting system,
lamp replacement. (05 Lamps/light bulbs,
hrs.) Lamp/light bulb
90. Check horn, head light and information, Indicators,
indicator and rectify the Headlights, Circuit
circuit. (05 hrs.) diagrams. (11 hrs.)
91. Practice on adjusting head
light focus. Identifying
wiring harness. (05 hrs.)
Professional Check ignition circuit 92. Inspection of spark plug Troubleshooting procedure
Skill 25 Hrs.; for proper gap and adjustments. (05 - for No sparks at plugs,
functioning. hrs) Engine starts but runs
Professional (Mapped NOS: 93. Measurement the poorly,
Knowledge 04 ASC/N1420) resistance of the ignition - No lights come on when
Hrs. primary and secondary ignition switch is turned
coil. (02 hrs.) ON,
94. Perform checking the - All lights come on but
performance of ignition dimly when ignition switch
coil, (03 hrs.) is turned ON
95. Inspect of A.C generator, - Headlight beams do not

28
Mechanic Two & Three Wheeler

practice on removal of shift when HI-LO switch is

C.D.I unit (Capacitive operated. Misfiring. (04
Discharge Ignition), hrs.)
inspection of C.D.I unit
and assembling. (05 hrs.)
96. Servicing of electronic
Ignition system,
Inspection of ignition
timing and adjustment.
(05hrs.)
97. Inspect ignition switch,
handlebar switches, front
brake & rear brake
stoplight light switch. (05
hrs.)
Professional Overhaul the 98. Identify the various parts - Study about LPG / CNG
Skill 25 Hrs.; LPG/CNG fuel of LPG/ CNG kit and powered engines used in
system and check Troubleshooting of the Three Wheelers. Safety
Professional exhausts smoke. same. (10 hrs.) while handling gas units.
Knowledge 07 (Mapped NOS: 99. Practice on Starting Emission Control-
Hrs. ASC/N9430) engine, tuning for slow - Sources of emission,
speed, perform exhaust Combustion,
emission test using gas Hydrocarbons,
analyzer/smoke tester and Hydrocarbons in exhaust
tuning the vehicle for gases, Oxides of nitrogen,
recommended emission Particulates, Carbon
levels. (15 hrs.) monoxide, Carbon dioxide,
Sulphur content in fuels,
crankcase emission control
system, Evaporative
emission control,
- Catalytic converter
Regulated emissions
standard. (07 hrs.)
Professional Familiarisation with 100. Locate the F1 system - Purpose of F1 system in
Skill 56 Hrs.; service Fuel components. two and three wheelers.
Injection system. 101. Remove tests and refit - Identify the various like
Professional (Mapped NOS: 102. Carryout ECM scan by IAP, MAP, Oxyzen, TA and
Knowledge-10 ASC/N9432) multi scan tool. its working principles.
Hrs. - Fuel injector and working
principles.
Professional Carryout servicing 103. Electric 2 & 3 Wheler Introduction: Electric
Skill 25 Hrs.; and maintenance of Maintenance Operate Vehicle
electric two and equipment according to Electric Vehicle

29
Mechanic Two & Three Wheeler

Professional three wheelers. safety protocols and Architecture Design

Knowledge 07 (Mapped NOS: identify tools, tests Electric Drive and controller
Hrs. ASC/N9431) equipment and service Energy Storage Solutions
procedures used in the (ESS)
servicing of EV. (04 hrs.) Battery Management
104. Identify basic propulsion System (BMS)/Energy
systems and power Management System (EMS)
transfer systems including Control Unit: Function of
AC and DC motor CU, Development Process.
technology used in EV (04 (07 hrs.)
hrs.)
105. Diagnose, repair, and test
power electronic circuitry
for electric drive systems.
(04hrs.)
106. Diagnose, repair, and test
motor control electronic
hardware. (04hrs.)
107. Diagnose, repair, and test
high voltage battery
systems. (04hrs.)
108. Perform safe storage,
handle, and dispose of
high voltage battery
systems and Check
Inverter Assembly variable
voltage system. (05hrs.)
Engineering Drawing: 40 Hrs.
Professional Read and apply ENGINEERING DRAWING:
Knowledge engineering drawing Introduction to Engineering Drawing and Drawing Instruments-
ED- 40 Hrs. for different Conventions
application in the Sizes and layout of drawing sheets
field of work. Title Block, its position and content
Drawing Instrument
Lines- Types and applications in drawing
Free hand drawing of –
Geometrical figures and blocks with dimension
Transferring measurement from the given object to the free
hand sketches.
Free hand drawing of hand tools and measuring tools.
Drawing of Geometrical figures:
Angle, Triangle, Circle, Rectangle, Square, Parallelogram.
Lettering & Numbering – Single Stroke.
Dimensioning

30
Mechanic Two & Three Wheeler

Types of arrowhead
Leader line with text
Position of dimensioning (Unidirectional, Aligned)
Symbolic representation –
Different symbols used in the related trades of Mechanic Auto
Body Repair / Electrical and Electronics / Diesel / Tractor / Two
and Three-wheeler.
Concept and reading of Drawing in Concept of axes plane and
quadrant
Concept of Orthographic and Isometric projections
Method of first angle and third angle projections (definition and
difference)
Reading of Job drawing related to Mechanic Auto Body
Repair / Electrical and Electronics / Diesel / Tractor / Two and
Three-wheeler trades.
Workshop Calculation & Science: 28 Hrs.
Professional Demonstrate basic WORKSHOP CALCULATION & SCIENCE:
Knowledge mathematical Unit, Fractions
WCS- 28 Hrs. concept and Classification of unit system
principles to Fundamental and Derived units F.P.S, C.G.S, M.K.S and SI units
perform practical Measurement units and conversion
operations. Factors, HCF, LCM and problems
Understand and Fractions - Addition, substraction, multiplication & division
explain basic science Decimal fractions - Addition, subtraction, multilipication &
in the field of study. division
Solving problems by using calculator
Square root, Ratio and Proportions, Percentage
Square and suare root
Simple problems using calculator
Applications of pythagoras theorem and related problems
Ratio and proportion
Ratio and proportion - Direct and indirect proportions
Percentage
Precentage - Changing percentage to decimal and fraction
Material Science
Types metals, types of ferrous and non ferrous metals
Physical and mechanical properties of metals
Properties and uses of rubber and insulating materials
Speed and Velocity, Work, Power and Energy
Speed and velocity - Rest, motion, speed, velocity, difference
between speed and velocity, acceleration and retardation
Speed and velocity - Related problems on speed & velocity
Work, power, energy, HP, IHP, BHP and efficiency
Basic Electricity

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Mechanic Two & Three Wheeler

Introduction and uses of electricity, molecule, atom, how

electricity is produced, electric current AC,DC their
comparison, voltage, resistance and their units
Conductor, insulator, types of connections - series and parallel
Ohm's law, relation between V.I.R & related problems
Electrical power, HP, energy and units of electrical energy
Levers and Simple machines
Lever & Simple machines - Lever and its types
Trigonometry
Measurement of angles
Trigonometrical ratios
Project Work/ Industrial Visit-
Broad area:
a) Overhauling of valve train
b) Overhauling of cylinder head
c) Maintenance of Electrical/ Electronics systems.
d) Brake system (Hydraulic & Air) & Hydraulic Power Steering

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Mechanic Two & Three Wheeler

SYLLABUS FOR CORE SKILLS

1. Employability Skills (Common for all CTS trades) (120 Hrs)

Learning outcomes, assessment criteria, syllabus and Tool List of Core Skills subjects which is
common for a group of trades, provided separately in www.bharatskills.gov.in / dgt.gov.in

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Mechanic Two & Three Wheeler
ANNEXURE-I

List of Tools and Equipment

MECHANIC TWO & THREE WHEELER (For the batch of 20 candidates)

S No. Name of the Tool & Equipment Specification Quantity

A. TRAINEES TOOL KIT per 4 Trainees

1. Allen Key set of 12 pieces 2mm to 14mm (5 +1) Nos.
2. Caliper inside Spring 15 cm (5 +1) Nos.
3. Calipers outside spring 15 cm (5 +1) Nos.
4. Center Punch 10 mm. Dia. x 100 mm. (5 +1) Nos.
5. Dividers Spring 15 cm (5 +1) Nos.
6. Electrician Screw Driver 250mm (5 +1) Nos.
7. Hammer ball peen with handle 0.5 kg (5 +1) Nos.
8. Hands file, Second cut flat 20 cm. (5 +1) Nos.
Philips Screw Driver set of 5 100 mm to 300 mm (5 +1) Nos.
9.
pieces
10. Pliers combination 20 cm (5 +1) Nos.
11. Screw driver 20cm.X 9mm. Blade (5 +1) Nos.
12. Screw driver 30 cm. X 9 mm. Blade (5 +1) Nos.
13. Scriber 15 cm (5 +1) Nos.
14. Spanner D.E. set of 12 Metric sizes6mm to 32mm (5 +1) Nos.
15. Spanner, ring set of 12 Metric sizes 6 to 32 mm. (5 +1) Nos.
Spanners socket with speed up to 32 mm set (5 +1) Nos.
16. handle, T-bar, ratchet and
universal of 28 pieces with box
17. Steel rule 30 cm inch and metric (5 +1) Nos.
Steel tool box with lock and key 400x200x150 mm (5 +1) Nos.
18.
(folding type)
19. Wire cutter and stripper (5 +1) Nos.
B. TOOLS INSTRUMENTS AND GENERAL SHOP OUTFITS
20. Adjustable spanner pipe wrench 350 mm 2 Nos.
Air blow gun with standard 1 No.
21.
accessories
Air impact wrench with 4 Nos.
22.
standard accessories
Air ratchet with standard 4 Nos.
23.
accessories

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Mechanic Two & Three Wheeler

24. Allen Key set of 12 pieces 2mm to 14mm 4 Nos.

Ammeter DC with external 300A/ 60A 4 Nos.
25.
shunt
26. Angle plate adjustable 250x150x175 mm 1 No.
27. Angle plate size 200x100x200mm 2 Nos.
28. Anvil with Stand 50 Kgs 1 No.
29. Auto Electrical test bench 1 No.
30. Battery –charger 2 Nos.
31. Blow Lamp 1 litre 2 Nos.
32. Caliper inside Spring 15 cm 4 Nos.
33. Calipers outside spring 15 cm 4 Nos.
Car Jet washer with standard 1 No.
34.
accessories
35. Chisel flat 10 cm 4 Nos.
36. Chisels cross cut 200 mm X 6mm 4 Nos.
Circlip pliers Expanding and 15cm and 20cm 4 Nos.
37.
contracting type
38. Clamps C 100mm 2 Nos.
39. Clamps C 150mm 2 Nos.
40. Clamps C 200mm 2 Nos.
41. Cleaning tray 45x30 cm. 4 Nos.
Compression testing gauge 2 Nos.
42. suitable for petrol engine. with
standard accessories
43. Copper bit soldering iron 0.25 Kg 4 Nos.
44. Cylinder bore gauge 20 to 160 mm capacity 2 Nos.
45. Cylinder bore gauge capacity 20 to 160 mm 2 Nos.
46. Depth micrometer 0-25mm 4 Nos.
Dial gauge type 1 Gr. A 4 Nos.
47. (complete with clamping
devices and stand)
48. Dividers Spring 15 cm 4 Nos.
49. Drift Punch Copper 15 Cm 4 Nos.
50. Drill point angle gauge 1 No.
Drill twist 1.5 mm to 15 mm (various sizes) by 4 Nos.
51.
0.5 mm
52. Electric Soldering Iron 230 V 60 watts 230 V 25 watts 2 each
53. Electric testing screw driver 4 Nos.
54. Engineer’s square Blade 15 cm. 4 Nos.

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Mechanic Two & Three Wheeler

55. Feeler gauge 20 blades (metric) 4 Nos.

56. File flat bastard 20 cm 4 Nos.
57. File, half round second cut 20 cm 4 Nos.
58. File, Square second cut 20 cm 4 Nos.
59. File, Square round 30 cm 4 Nos.
60. File, triangular second cut 15 cm 4 Nos.
Files assorted sizes and types 2 sets
61. including safe edge file (20
No’s)
62. Flat File second cut 25 cm 4 Nos.
63. Flat File bastard 35 cm 4 Nos.
Granite surface plate with stand 1600 x 1000mm 1 No.
64.
and cover
65. Grease Gun 2 Nos.
66. Growler 1 No.
67. Hacksaw frame adjustable 20-30 cm 10 Nos.
68. Hammer Ball Peen 0.75 Kg 4 Nos.
69. Hammer Chipping 0.25 Kg 5 Nos.
Hammer copper 1 Kg with 4 Nos.
70.
handle
71. Hammer Mallet 3 Nos.
72. Hammer Plastic 4 Nos.
Hand operated crimping tool (i) 2 Nos.
73. for crimping up to 4mm and (ii)
for crimping up to 10mm
Hand reamers adjustable 10.5 to 11.25 mm, 11.25 to 12.75 2 sets
74. mm, 12.75 to 14.25 mm and 14.25
to 15.75 mm
75. Hand vice 37 mm 2 Nos.
Hollow Punch set of seven 6mm to 15mm 2 sets each
76.
pieces
77. Insulated Screw driver 20 cm x 9mm blade 4 Nos.
78. Insulated Screw driver 30 cm x 9mm blade 4 Nos.
Magneto spanner set with 8 1 set
79.
spanners
80. Magnifying glass 75mm 2 Nos.
81. Marking out table 90X60X90 cm. 1 No.
82. Multimeter digital 5 Nos.
83. Oil can 0.5/0.25-liter capacity 4 Nos.

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Mechanic Two & Three Wheeler

84. Oil Stone 15 cm x 5 cm x 2.5 cm 1 No.

85. Outside micrometer 0 to 25 mm 4 Nos.
86. Outside micrometer 25 to 50 mm 4 Nos.
Outside micrometer 50 to 75 1 Nos.
87.
mm
88. Outside micrometer 75 to 100 mm 1 Nos.
Philips Screw Driver set of 5 (100 mm to 300 mm) 2 sets
89.
pieces
90. Piston ring compressor 2 Nos.
Piston Ring expander and 2 Nos.
91.
remover.
92. Piston Ring groove cleaner. 2 Nos.
93. Pliers combination 20 cm. 2 Nos.
94. Pliers flat nose 15 cm 2 Nos.
95. Pliers round nose 15 cm 2 Nos.
96. Pliers side cutting 15 cm 2 Nos.
97. Portable electric drill Machine 1 No.
98. Power Supply 0-12 v, lamp 1 No.
99. Prick Punch 15 cm 4 Nos.
100. Punch Letter 4mm (Number) 2 sets
101. Right cut snips 250mm 2 Nos.
Rivet sets snap and Dolly 3mm, 4mm, 6mm 2 Nos.
102.
combined
Scooter / Motor cycle repairing 2 Nos.
103.
stand
104. Scraper flat 25 cm 2 Nos.
105. Scraper half round 25 cm 2 Nos.
106. Scraper Triangular 25 cm 2 Nos.
107. Scriber 15 cm 2 Nos.
Scriber with scribing black 2 Nos.
108.
universal
Set of stock and dies - UNC, 2 sets
109.
UNF and metric
110. Soldering Copper Hatchet type 500gms 2 Nos.
Solid Parallels in pairs (Different 2 Nos.
111.
size) in Metric
112. Spanner Clyburn 15 cm 1 No.
113. Spanner D.E. set of 12 pieces 6mm to 32mm 4 Nos.
114. Spanner T. flocks for screwing 2 Nos.

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Mechanic Two & Three Wheeler

up and up-screwing
inaccessible positions
115. Spanner, adjustable 15cm. 2 Nos.
Spanner, ring set of 12 metric 4 Nos.
116.
sizes 6 to 32 mm.
Spanners socket with speed 2 Nos.
handle, T-bar, ratchet and
117.
universal up to 32
mm set of 28 pieces with box
118. Spark lighter 2 Nos.
119. Spark plug spanner 2 Nos.
Steel measuring tape 10 meter 4 Nos.
120.
in a case
Steel rule 15 cm inch and 4 Nos.
121.
metric
Steel rule 30 cm inch and 4 Nos.
122.
metric
123. Straight edge gauge 2 2 Nos.
124. Stud extractor set of 3 2 sets
Stud remover with socket 1 No.
125.
handle
Surface gauge with dial test 4 Nos.
126. indicator plunger type i.e. 0.01
mm
127. Tachometer (Counting type) 1 No.
Taps and Dies complete sets 1 set
128.
BSF
129. Taps and wrenches - Metric 2 sets
130. Telescope gauge 4 Nos.
131. Temperature gauge 0-100 deg c 2 Nos.
132. Thread pitch gauge metric, BSW 2 Nos.
133. Torque wrenches 1 each
Tyre pressure gauge with 2 Nos.
134.
holding nipple
Universal puller for removing 1 No.
135.
pulleys, bearings
136. V’ Block with Clamps 75 x 38 mm pair 2 Nos.
137. Vacuum gauge 0 to 760 mm of Hg 2 Nos.
138. Valve Lifter 1 No.
Valve spring compressor 2 Nos.
139.
universal.

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Mechanic Two & Three Wheeler

Vernier caliper 0-300 mm with least count 4 Nos.

140.
0.02mm
141. Vice grip pliers 2 Nos.
142. Voltmeter 50V/DC 2 Nos.
143. Wire Gauge (metric) 2 Nos.
Work bench with 4 vices 12cm 250 x 120 x 60 cm 4 Nos.
144.
Jaw
C. GENERAL INSTALLATION/ MACHINERIES
Arbor press hand operated 2- 1 No.
145.
ton capacity
Automotive exhaust 5 gas 1 No.
146.
analyzer (petrol )
147. Battery tester to test 12V/ 24V 2 Nos.
Cut section working model of 1 No.
148. Continuous variable
transmission
Cut Section working model of 1 No.
149. Rotary clutch assembly of two
wheeler
Demonstration board of 1 No.
150. magneto ignition system of a
two wheeler
Discrete Component Trainer / 1 No.
151.
Basic Electronics Trainer
Drilling machine bench to drill 1 No.
152. up to 12mm dia along with
accessories
153. Gas Welding Table 1220mm x760mm 2 Nos.
Grinding machine (general 300 mm dia 1 No.
154. purpose) D.E. pedestal with
wheels rough and smooth
Ignition coil and CDI unit of four 1each
155.
different make
Layout of working model 12 V 1 each
156.
automobile electrical systems
Motor cycle (four stroke 1 No.
157.
engine) with Digital twin spark
158. Motor vehicle ( 3 wheeler) 1 No.
159. Scooter (four stroke engine) 1 No.
shock absorber for two wheeler 2 Nos.
160.
four different type

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Mechanic Two & Three Wheeler

161. Spring tension tester 1 No.

Three wheeler chassis frame & 1 No.
162.
power transmission system.
Three wheeler Engine for 2 Nos.
163.
dismantling and assembling
Three wheeler gear box for 2 Nos.
164.
dismantling and assembling
Three wheeler steering system 2 Nos.
165.
for dismantling and assembling
Trolley type portable air 1 No.
166. compressor single cylinder with
45
capacity Air tank, along with 2 Nos.
167.
accessories & with working
Working model of electronic 1 No.
168. ignition system of three
wheeler
Working model of electronic 1 No.
169.
ignition system of two wheeler
Desktop Computer CPU: 32/64 Bit i3/i5/i7 or latest 2 Nos.
processor, Speed: 3 GHz or Higher.
RAM:-4 GB DDR-III or Higher, Wi-Fi
Enabled. Network Card: Integrated
170. Gigabit Ethernet, with USB Mouse,
USB Keyboard and Monitor (Min.
17 Inch. Licensed Operating
System and Antivirus compatible
with trade related software.
Internet connection with all As required
171.
accessories
172. Laser printer 1 No.
173. LCD projector/ LED /LCD TV 42” 1 No.
174. Online UPS 2KVA As required
Motor Cycle with liquid cooling 1 No.
175. system and fuel Injection
system
D. LIST OF CONSUMABLE:
176. Automatic Transmission oils As required
177. Battery- SMF As required
178. Brake fluids As required
179. Chalk, Prussian blue. As required

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Mechanic Two & Three Wheeler

Chemical compound for As required

180.
fasteners
181. Diesel As required
182. Different type gasket material As required
183. Different type of oil seal As required
184. Drill Twist (assorted) As required
185. Emery paper - 36–60 grit , 80–120 grit As required
186. Engine coolant As required
187. Engine oil As required
188. Gear oils As required
Gloves for Welding (Leather 5 sets
189.
and Asbestos)
190. Hacksaw blade (consumable) As required
Hand rubber gloves tested for 5 pairs
191.
5000 V
Holders, lamp teakwood As required
boards, plug sockets, solders,
192. flux wires and cables batteries
round consumable blocks and
other consumables as required
193. Hydrometer 4 Nos.
194. Lapping abrasives As required
195. Leather Apron 5 Nos.
196. Petrol As required
197. Power steering oil As required
198. Radiator Coolants As required
199. Safety goggles As required
200. Steel wire Brush 50mmx150mm 5 Nos.
E. WORKSHOP FURNITURE
201. Book shelf (glass panel) 6½ ‘ x 3’ x 1½’ As required
202. Computer Chair 2 Nos.
203. Computer Table 2 Nos.
204. Discussion Table 8’ x 4’ x 2½ ‘ 2 Nos.
205. Fire Extinguishers, first- aid box As required
Instructional Material – NIMI As required
206.
Books/Ref.books
Multimedia DVD for As required
207. Automotive application /
subjects

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Mechanic Two & Three Wheeler

208. Stools 21(20 +1) Nos.

209. Storage Rack 6½ ‘ x 3’ x 1½’ As required
210. Storage shelf 6½ ‘ x 3’ x 1½’ As required
211. Suitable class room furniture As required
212. Suitable Work Tables with vices As required
213. Tool Cabinet 6½ ‘ x 3’ x 1½’ 2 Nos.
214. Trainees locker ( 20 lockers) 6½ ‘ x 3’ x 1½’ 2 Nos.
Note: -
1. Internet facility is desired to be provided in the class room.

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Mechanic Two & Three Wheeler

ABBREVIATIONS
CTS Craftsmen Training Scheme
ATS Apprenticeship Training Scheme
CITS Craft Instructor Training Scheme
DGT Directorate General of Training
MSDE Ministry of Skill Development and Entrepreneurship
NTC National Trade Certificate
NAC National Apprenticeship Certificate
NCIC National Craft Instructor Certificate
LD Locomotor Disability
CP Cerebral Palsy
MD Multiple Disabilities
LV Low Vision
HH Hard of Hearing
ID Intellectual Disabilities
LC Leprosy Cured
SLD Specific Learning Disabilities
DW Dwarfism
MI Mental Illness
AA Acid Attack
PwD Person with disabilities

43
Mechanic Two & Three Wheeler

44