Baba automobile training centre

Baba Automobile Training Workshop is a Training company (Registered in Ministry of Micro &
Small & Medium Enterprises “MSME”, & An ISO 9001:2015 Certified Company) providing
practical knowledge to engineering students and generating need of training in the minds of students
in the field of Mechanical, Automobile so that student can get good position in the Industries. Our
training workshop is well known for providing Practical education in the advanced fields such as
Automobile Training (Fully Assemble or disassemble the car by student), I.C Engine Training (2-
stroke, 4-stroke, 6-stroke single and multi-cylinder petrol and diesel engine.), Car or Bike
Modification Training, Go-kart Development training (Student Formula-1 car generation), Space and
Advanced Project Development Training, Car Transformer Robot Training. Currently, these are the
hottest and largest job-providing sector.

About automobile industry in India

Baba Automobile Training Workshop is a Training company (Registered in Ministry of Micro &
Small & Medium Enterprises “MSME”, & An ISO 9001:2015 Certified Company) providing
practical knowledge to engineering students and generating need of training in the minds of students
in the field of Mechanical, Automobile so that student can get good position in the Industries. Our
training workshop is well known for providing Practical education in the advanced fields such as
Automobile Training (Fully Assemble or disassemble the car by student), I.C Engine Training (2-
stroke, 4-stroke, 6-stroke single and multi-cylinder petrol and diesel engine.), Car or Bike
Modification Training, Go-kart Development training (Student Formula-1 car generation), Space and
Advanced Project Development Training, Car Transformer Robot Training. Currently, these are the
hottest and largest job-providing sector.
 2-wheeler engine and parts

Internal combustion engine -The principle behind any reciprocating internal

combustion engine: If you put a tiny amount of high-energy fuel (like gasoline) in a small, enclosed
space and ignite it, an incredible amount of energy is released in the form of expanding gas. You can
use that energy to propel a potato 500 feet. In this case, the energy is translated into potato motion.
You can also use it for more interesting purposes. For example, if you can create a cycle that allows
you to set off explosions like this hundreds of times per minute, and if you can harness that energy in
a useful way, what you have is the core of a car engine!

Almost all cars currently use what is called a four stroke combustion cycle to convert gasoline into
motion. The four-stroke approach is also known as the Otto cycle, in honor of Nikolaus Otto, who
invented it in 1867.

 Intake stroke

 Compression stroke

 Power stroke

 Exhaust stroke

Spark plug -The spark plug supplies the spark that ignites the air/fuel mixture so that
combustion can occur. The spark must happen at just the right moment for things to work properly.

Valve -The intake and exhaust valves open at the proper time to let in air and fuel and to let out
exhaust. Note that both valves are closed during compression and combustion so that the combustion
chamber is sealed.

Piston -A piston is a cylindrical piece of metal that moves up and down inside the cylinder.
Piston rings -Piston rings provide a sliding seal between the outer edge of the piston and the
inner edge of the cylinder. The rings serve two purposes:

 They prevent the fuel/air mixture and exhaust in the combustion chamber from leaking into the
sump during compression and combustion.
 They keep oil in the sump from leaking into the combustion area, where it would be burned and
lost.
Connecting rod -The connecting rod connects the piston to the crankshaft. It can rotate at
both ends so that its angle can change as the piston moves and the crankshaft rotates.

Crank shaft -The crankshaft turns the piston up and down motion into circular motion just like
a crank on a jack-in-the-box does.

Transmission in 2 wheeler engine

Transmission is defined as a mechanical assembly (machine) that transmits power from the Engine to
the Final Drive. The simplest transmissions can have just one, fixed ratio and no shifting. This article
will expose the detailed workings of the 6-speed motorcycle transmission, but the 4 and 5 speeds
work the same way.
Power is applied to the Input Shaft (pinion/drive shaft) of the transmission by the Clutch when it is
engaged (plates and disc sandwiched together) and the Engine is running. The input / drive shaft turns
anytime and all the time that the clutch is engaged. There is a drive/pinion gear for each ratio (gear
change).
The input shaft gears mesh with their corresponding Driven Gears that ride on the Output/Driven
Shaft. Motorcycles use Constant Mesh type transmissions. This name comes from the fact that the
“gear pairs” are always meshed. These gear Sets/Pairs provide the gearing ratio changes that we use
to go from stand-still to top speed, and in our case a high transmission ratio of 3.1:1 for our 1st gear
and 0.8:1 for our 6th gear.
The 3.1:1 Ratio of 1st means that the Input Shaft must make 3.1 revolutions for every 1 revolution of
the Output Shaft (shaft where the front sprocket attaches).
The 0.8:1 Ratio of 6th means that just 8 revolutions of the Input Shaft results in 1 full revolution of
the Output Shaft.

A Transmission is defined as a mechanical assembly (machine) that transmits power from the Engine
to the Final Drive. The simplest transmissions can have just one, fixed ratio and no shifting. This
article will expose the detailed workings of the 6-speed motorcycle transmission, but the 4 and 5
speeds work the same way.
Power is applied to the Input Shaft (pinion/drive shaft) of the transmission by the Clutch when it is
engaged (plates and disc sandwiched together) and the Engine is running. The input /drive shaft turns
anytime and all the time that the clutch is engaged. There is a drive/pinion gear for each ratio (gear
change).
The input shaft gears mesh with their corresponding Driven Gears that ride on the Output/Driven
Shaft. Motorcycles use Constant Mesh type transmissions. This name comes from the fact that the
“gear pairs” are always meshed. These gear Sets/Pairs provide the gearing ratio changes that we use
to go from stand-still to top speed, and in our case a high transmission ratio of 3.1:1 for our 1st gear
and 0.8:1 for our 6th gear.
The 3.1:1 Ratio of 1st means that the Input Shaft must make 3.1 revolutions for every 1 revolution of
the Output Shaft (shaft where the front sprocket attaches).
The 0.8:1 Ratio of 6th means that just .8 revolutions of the Input Shaft results in 1 full revolution of
the Output Shaft.

Yoke cam - The yoke cam has “worm channels” cast or machined into the surface. These
channels provide and manage the directional control for each of the Shift yoke. As the yoke cam
rotates, the channels hold or move the Forks right or left to engage and disengage the different splined
gear sets.
Oil pump and its working - oil pump maintain steady oil pressure inside your
motor in order to keep lubricant flowing to each and every component, crevice and channel built into
the unit. To do this, an oil pump that is capable of generating the right psi, or pounds per square inch
of oil pressure is required. Think of it as the heart of your engine ensuring that lubricant never stops
flowing..

Clutch – Motorcycles typically employ a wet clutch with the clutch riding in the same oil as the
transmission. A multiple plate clutch is a type of clutch system where multiple driven and drive
plates are used in order to make up for torque loss due to slippage. This slippage is usually caused by
a fluid that the plates are immersed in for cooling , cleaning and lubrication. This type of clutch
system is commonly referred to as a wet clutch system. The type of arrangement is what is found in
the automatic transmission in your car. This clutch system allows gears to be shifted up and/or down,
without interrupting the power flow through the transmission, by lifting the accelerator.
 Honda shine engine
Specification
 Displacement :- 125CC
 Maximum power :- 10bhp@7500 rpm
 Maximum torque :-11Nm@5500rpm
 Mileage :-55kmpl
 On road price :-58,090
 Bore :- 52mm
 Stroke :- 58mm
 No of gear :- 4
Quality
Honda shine engine is much silent than bike because Honda provide a cut section (45degree)
In block of engine which decrease air pressure over crank shaft and provide smooth running.
This bike has one unique feature that it will start even in gear.
Transmission
Honda shine have constant mesh gear transmission in which gear no. 1 &3 are fixed on input shaft
And gear no 2 &4 are fixed over on output shaft. Gear are controlled with dog clutch which moves in
path of yoke cam with the help of yoke.
Crank rotate =7 times of kick gear
Oil pump
Oil pump took drive from pinion gear and lubricate cam and crank.
 TVS sport (2008)
Specification
 Displacement :-100cc
 Maximum power :-7.4bhp@7500rpm
 Maximum torque :-7.5bhp@5000rpm
 Mileage :-95kmpl
 Wet multi plate clutch
 Bore :- 51mm
 Stroke :- 48mm
 No. of gear :-4
 Price :- 39,000
Quality
The TVS Star Sport, is, as the name suggests, a sportier version of the TVS Star City. The TVS Star
Sport, when compared to the standard bike, gets sportier graphics as well as a racier front cowl in a
bid up the sportiness. It is available in two variants-electric start and kick start.

Transmission
Sport transmission gear arranged in alternative order which have input gear no 1&3 are fixed on input
shaft and output gear no 2&4 are fixed on output shaft.

Kick gear – o/p shaft 1st gear – i/p shaft 1st gear – clutch- pinion gear
Oil pump
Oil pump is same as Honda shine (G-motor) which took drive from pinion gear
 Hero Honda splendour
Specification
 Displacement :- 97.7cc
 Maximum power :-8.24bhp
 Maximum torque :-8.05Nm
 Air cooled
 Mileage :- 80.6kmpl
 Price :- 45-48,000
Quality
It is horizontal type engine which engine have complete clearance of exhaust gas and reduce tendency
to knock but this type of engine is not for higher cc engine . its yoke cam is slightly different from
other bike engine.

Transmission
Splendour gear are arranged in alternative order which have input gear no 1&3 are fixed on input
shaft and output gear no 2&4 are fixed on output shaft.

Crank rotation = 7 times of kick gear

Oil pump
Splendour oil pump rotate with the help of timing chain and timing chain is controlled by tensioner
and idlear.
 LML freedom
Specification
 Displacement :- 109cc
 Cylinder :- 1
 Maximum power :-8.5bhp@7750rpm
 Maximum torque :-8.6Nm@5000rpm
 Fuel type :-petrol
 Wet multi plate clutch
 Mileage :- 65kmpl
 Price :-50000

LML have same function as above bikes

 Bajaj pulsar NS 220
Pulsar are used as sports bike because they have speed not mileage
Specification
 Mileage :-38kmpl
 Displacement :-220cc
 Maximum power :- 21bhp@85000rpm
 Maximum torque :- 19Nm@7000rpm
 Fuel :- petrol
 Air cooled
 Wet multi plate clutch
 Price :- 90000
Quality
NS 220 have twin spark ignition which produce more power in bike and increase speed of bike
therefore its mileage is much low than previous bike.

Transmission
Honda shine have constant mesh gear transmission in which gear no. 1 &3 are fixed on input shaft
And gear no 2 &4 are fixed over on output shaft. Gear are controlled with dog clutch which moves in
path of yoke cam with the help of yoke.
 TVS Victor
Specification
 Mileage :-72kmpl
 Displacement :-109.7cc
 Power :-9.6ps@7500rpm
 Torque :-9.4Nm@6000rpm
 Bore :- 53.5mm
 Stroke :-48.8mm
 Price :-53,295

Quality
It has very good fuel efficiency it gives almost 65kmpl in daily life commuting. It has good pickup as
well as very comfortable to ride. This bike has one unique feature that it will start even in gear and its
star connection is quite similar to Honda splendour

Transmission
Victor gear arrangement is same as Honda shine in which input gear arranged in size increased order
while output gear arranged in decreasing size order. Input gear no 1 & 2 are fixed on input shaft and
output gear no 3& 4 are fixed on output shaft.
(Crank rotate = 6 times of kick gear)

Kick gear –intermediate gear –compound gear –outer housing –pinion gear
 Bajaj Pulsar 150
Specification
 Displacement :- 149cc
 Mileage :- 65kmpl
 Maximum power :- 15bhp@9000rpm
 Maximum torque :- 12Nm@6500rpm
 Bore :- 57mm
 Stroke :-56mm
 No of gear :-5
 Price :-74,000

Quality
Pulsar 150 have 5 gear transmission which produce too much vibration so to absorb this vibration
engine have jerk gear who rotate counter weight shaft attached with gear and absorb shock.

Transmission
Pulsar input and output shaft mounted by 5 gear transmission in which input have gear no 1,3&5 are
fixed on input shaft and dog clutch is mount on gear 3 while output have gear no 4&5 are fixed on
output shaft and dog is mount over gear 4& 5.

Kick gear – output 1st gear –input 1st gear – clutch – crank shaft
 Suzuki samurai (two Stroke)

Specification
 Displacement :- 98.2cc
 No of stroke :-2
 Power :-7.9ps @5500rpm
 Torque :-9.8Nm @5000rpm
 Bore :- 50mm
 Stroke :-50mm
 Gear :- 4

engine sucks the air fuel mixture when piston move from BDC to TDC from one way valve through
craburetor. Chamber have transfer and exhaust port in which exhaust port is slightly above the
transfer port .

Transmission
four gear mount on each shaft in which input have gear no 1 &2 of input are fixed on input shaft and
output gear no 3&4 are fixed on output shaft. Its clutch is formed by tension spring which is
controlled by crank pin from left hand side of engine via small diameter wire.

Oil pump
Samurai have two oil tank one for lubrication of transmission gear by splashing and other for
lubrication of crank shaft which suck by oil pump and umped towards the inlet of air fuel mixture
port.
Oil pump have worm gear mechanism which suck oil from inlet and exhaust it from nozzle through
small diameter pipe.
 Honda Eterno (scooter)

Specification
 Mileage :-60kmpl
 Displacement :-147.7cc
 Gear :- 4
 Maximum power :-8.2bhp@6000rpm
 Maximum torque :-10.63Nm@4000rpm
 Bore :-57mm
 Stroke :-57mm
Scooter valves are different from bike because of their silencer position and engine mounting.
Fan is also provide for scooter engine who exhaust heat from engine.

Quality
Scooter output shaft is directly connect to rear wheel with drum brake therefore have much
more torque than bikes .

Transmission
All input gear are fixed over input shaft while all output gear are free over output shaft. Dog
clutch is connect with spring which moves internally in output shaft and fixed with gear
because scooter gear mechanism is controlled by hand.

Kick gear –input 1st gear –clutch – pinion gear

Oil pump
Its oil pump is rotate with clutch because they are locked with each other and its oil pump is of
g motor type.