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VISVESVARAYA TECHNOLOGICAL UNIVERSITY

JNANA SANGAMA, BELAGAVI-590018

Internship Report
On
SERVICE OF TWO-WHEELER (ACTIVA)
At
SRI HONDA HASSAN -573201

Submitted in partial fulfillment of the requirement for the


Award of degree of

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

Submitted By

SHARATH BABU N

(4HG20ME423)

Under the guidance of

Dr.Manjunath.K

Assistant professor

DEPARTMENT OF MECHANICAL ENGINEERING

GOVERNMENT ENGINEERING COLLEGE

MOSALE HOSAHALLI-573212
2022-2023
SRI HONDA COMPANY CERTIFICATE
ACKNOWLEDGEMENT
I express my most sincere grateful thanks to my Internship Guide, Dr.Manjuanth.K,Assistant
Professor ,Department of Mechanical Engineering, Government Engineering College
Mosale hosahalli, Hassan for his continuous support and advice not only during the course of our
internship but also during the period of stay in GECMH.

I express my most sincere grateful thanks to my External Internship Guide Sri MANU,
Manager of Sri Honda Shantesha Scooter Agency Pvt.Lyd Showroom Thanniruhalla
Hassan-573201 for his constant support and advice during the course of my internship at Sri
Honda Showroom Thanniruhalla Hassan.

I wish to express my gratitude to Dr.MAHESH.T.S, Professor and Head Department of


Mechanical Engineering for his constant support and encouragement.

I express my most sincere grateful thanks to my Internship co-ordinate, Smt.Manjula.S


,Assistant Professor ,Department of Mechanical Engineering, Government Engineering
College Mosale hosahalli, Hassan for his continuous support and advice not only during the
course of our internship but also during the period of stay in GECMH.

I wish to express my thanks to beloved Dr.T.Rangaswamy, principal, Government


Engineering College Mosalehosahalli Hassan for his encouragement throughout studies.

Finally, I express my gratitude to all teaching and non-teaching staff of Department of Mechanical
Engineering, Fellow classmates and parents for their timely support and suggestions.

SHARATH BABU.N

(4HG20ME423)
CONTENS
CHAPTER 1 HONDA COMPANY PROFILE 1

1.1 Introduction to Honda Company 1

CHAPTER 2 HISTORY OF HONDA MOTOR COMPANY. 2

2.1 List of Honda Facilities 2

CHAPTER 3 MOTORCYCLE SERVICE 13

3.1 Motor Cycle Service Rules 13

3.2 Different Stages of Services 14

3.3 Different Steps of Lubrication 18

3.4 General Service 24

3.5 Final Inspection of Two-Wheeler 32


LIST OF FIGURES
Figure 1.1 Honda Company Hassan 1

Figure 1.2 Edward Butler 2

Figure 1.3 Motorcycle


3
Figure 1.4 Franz J 3
Figure 1.5 Benly J 4
Figure 1.20 Electric Vehicle 11
Figure 3.1 Inspection 14
Figure3.2 Visual Inspection 14
Figure 3.3 Tires Inspection 15
Figure3.4 Brake Inspection 15

Figure3. 5 Chain Inspections 16


Figure 3.6 Gear Inspections 16

Figure 3.21 Dry Bolt 29

Figure 3.22 Oil Strainer Screen Cap 29

Figure 3.41 First Inspection 32


Figure 3.42 Final inspection 33
SERVICE OF TWO-WHEELR (ACTIVA) AT SRI HONDA HAASAN

CHAPTER 1

HONDA COMPANY PROFILE

1.1 Introduction to Honda Company


Industry sector is also known as the secondary sector which is support the economic growth. The
automobile industry is one of the most important parts of industrial sector which is more support to increase
economic growth in respect of revenue in India. The Indian two wheeler industry made a small beginning in
the early 1950‟s. India is the second largest manufacturer and producer of two-wheeler in the world. It stands
next to China and Japan.
Honda Motorcycle and Scooter India Private Limited is the 100% subsidiary of HONDA motor company
Japan- the world’s No.1 two wheeler companies. HONDA started its Indian two wheeler operation in May
2001. Honda Motorcycle and Scooter India Private Limited was established in 1999 at Manesar, District
Gurgaon, Haryana. „Wings‟ is the symbol of HONDA two wheeler with the „The Power OF Dreams‟ as their
slogan. In its 18th year HONDA has grown to become India’s second largest two wheeler company with over
42 million happy customers in India. Customers are king of the market. Business always starts and closes with
customers. All the business enhancement, profits, status, image etc. of the organization depends on customers.
Customer’s satisfaction is important for running a business. The satisfaction could be related to various
business aspects like marketing, quality of product, service provided by the company, customer’s problems
and queries etc.

Figure 1.1 Honda Company Hassan

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SERVICE OF TWO-WHEELR (ACTIVA) AT SRI HONDA HAASAN
CHAPTER 2

HISTORY OF HONDA MOTOR COMPANY

2.1 Edward Butler (1900)

An early motorcycle, c.1900.Just as the automobile was the answer to the 19th-century
dream of self-propelling the horse-drawn carriage, the invention of the motorcycle created the self-
propelled bicycle.

Figure 1.2 Edward Butler

2.2 Isle (1907)

The original Tourist Trophy motorcycle races were held on the Isle of Man in 1907 as reliability or
endurance races. Such events have been the proving ground for many new ideas from early two-
stroke-cycle designs to supercharged, multivalve engines mounted on aerodynamic, carbon-fibre
reinforced bodywork.

Figure 1.2 Isle

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2.3 Dale Vinten (1949)

1949 The company produces its first real motorcycle, powered by a 98cc a two-stroke motor. When
an employee sees the first one assembled and it is ridden outside the factory, he says, “It’s like a
dream.” The name “Dream” was adopted for the bike, officially known as Model D.

Figure 1.3 Motorcycle

2.4 Franz J (1952)

1952Despite the fact that he despises such “primitive” powerplants, Honda flirts with his original
notion of auxiliary motors for bicycles. The Cub F (two-stroke, 50cc) clip-on motor is sold through
thousands of independent bicycle shops across Japan. It is only manufactured for two years, but it
introduces the “Cub” trademark, which will be popular for decades in various guises.

Figure 1.4 Franz J

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2.5 Benly J (1953)

1953 The Benly J (4-stroke, 90cc) is released. At least some of these were sold with “Benly”
tank-badges, and carried the Honda name on engine cases only. The Benly series also lasted a long
time, and ushered in an era of improved performance. They were immediately popular with Japan’s
amateur racers.

Figure 1.5 Benly J

2.6 Fujisawa (1958)

1958 The Super Cub (aka C100, aka CA100, aka simply “the Honda 50”) hits the market. It
features a pressed-steel frame, leading-link fork, step-through design and a 50cc four-stroke motor.
It is destined to be sold under various names, and will later grow to 70cc, and finally 90cc. It will
become the most popular motorcycle–indeed, the most popular motor vehicle of any kind.

Figure 1.6 90CC

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2.7 Rieju (1959)

1959 Honda enters the famed Isle of Man TT races for the first time. The company fields five
machines in the 125cc “Ultra-lightweight” class. The bikes are 125cc twins, of the type raced the
previous year in Japanese national competition. Naomi Tanaguchi achieves the team’s the best TT
result, finishing sixth. Honda wins the manufacturer’s trophy in the class.

Figure 1.7 125CC

2.8 David Garside (1961)

1961 Honda dominates both the 125cc and 250cc classes at the TT. Mike Hailwood wins both
races, with Hondas finishing 1st through 5th positions in each case. The Isle of Man Examiner
newspaper says simply, “It was a devastating win for the Orient.”

Figure 1.8 250CC

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2.9 Stuart Barker (1964)

1964 Two-stroke motors begin to dominate the smaller-displacement racing classes. In order to
remain competitive in the 250cc classes, while still relying on four-stroke motors, Honda produces
a six-cylinder 250, the 3RC164. This engineering marvel dazzles the racing world, but it is not
enough to prevent Phil Read from winning the championship on his Yamaha ’stroker. In ’66 and
’67, however, Mike Hailwood will use the six to win the 250cc World Championship.

Figure 1.9 250CC

2.10 Bob Hansen (1969)

1969 Honda unveiled the CB750 at the Tokyo Motor Show in late ’68, but it didn’t hit the market
until early ’69. It is impossible to overstate the impact this bike made, as the first modern mass-
market four, and the first mass-market bike to come with a disc brake. Until well into 1970,
CB750s were made with sand-cast, not die-cast engine cases. In truth, die-cast cases were lighter,
stronger, and more oil tight. But it’s the sand-cast models that are prized by collectors.

Figure 1.10 CB750

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2.11 Husqvarna (1973)

1973 Honda finally admits that in order to build a competitive 250cc motocrosser, the company has
to make another two-stroke motor. CR250 “Elsinore” reaches the U.S. in early ’73. It is
immediately the most effective production race bike in its class, and Gary Jones wins the AMA
motocross championship on it in its first year.

Figure 1.11 CR250CC

2.12 Takazumi Katayama (1978)

1978 In an effort to build a competitive four-stroke motorcycle for the 500GP World
Championship, Honda produces the oval-piston NR500. It was effectively a “four-cylinder V-8,
with 8 connecting rods and 32 valves. It is a technological tour-de-force, but manufacturing
challenges prevent it from racing until late in the ’79 season. Honda persists with the machine
through the ’81 season, but even Freddie Spencer can’t manage to win on it.

Figure 1.12 NR500

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2.13 Gudmundur (1983)

1983 Freddie Spencer wins the 500cc World Championship. For the first time, Honda wins the
“blue riband” championship. (The company first won the Manufacturer’s Championship in the
500cc class in 1966.)

Figure 1.13 500CC

2.14 Ishikawa (1987)

1987 The CBR600F “Hurricane” is Honda’s first fully-faired, four-cylinder street bike.

Figure 1.14 CBR 600

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2.15 John (1993)

1993 the CBR900RR stuns the sportbike world. Designed by Tadao Baba, the “Fireblade”
combines the power of an open-class motorcycle with the weight and handling of a 600.

Figure 1.15 CBR900RR

2.16 Mizuno (1995)

1995 The radical EXP-2 (two-stroke 400cc) wins its class in the Granada-Dakar rally. The bike is
the proof-of-concept for a cleaner burning and more powerful two-stroke engine concept that uses a
pivoting “valve” to close the exhaust port.

Figure 1.16 400CC

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2.17 Valentino Rossi (2002)

2002 All change. Or not. Rossi wins the first World Championship in the 990cc MotoGP era, on
the five-cylinder four-stroke RC211V. Valentino Rossi wins the last ever 500cc World
Championship on the NSR500 two-stroke.

Figure 1.17 990CC

2.18 Honda 130 CC (2010)

Introduced in early 2009 as a 2010 model, Honda breaks the mold with the chopper-inspired Fury.
Powered by a 1300cc V-Twin, it’s something of a departure for the traditionally conservative
company.

Figure 1.18 130CC

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2.19 Bhushan Kushwah (2011-2019)

2011-2019 In an effort to tap into the burgeoning beginner-bike segment, the CBR250R is
introduced. Powered by a 249cc single-cylinder engine, the mini CBR is manufactured in Honda’s
Thailand plant and sold worldwide.

Figure 1.19 250R

2.20 Electric Vehicle (2022)

In March 2022, Honda announced it would develop and build electric vehicles in a joint venture
with Sony. The latter is set to provide its imaging, sensing, network and other technologies while
Honda would be responsible for the car manufacturing processes

Figure 1.20 Electric Vehicle

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SERVICE OF TWO-WHEELR (ACTIVA) AT SRI HONDA HAASAN

2.1 List of Honda Facilities

India

o Gurgaon, Haryana — Motorcycles & Scooters.

o Noida, Uttar Pradesh — Vehicle R&D, Cars, SUVs & Power products.

o Tapukara, Rajasthan — Motorcycles & Cars.

o Tapukara, Rajasthan — Power train.

o Narsapura, Karnataka — 2 Wheelers

o Vithalpur, Gujarat — Scooters.

2.2 Contact Details

SRI HONDA

Shantesha Scooter Agency Pvt.Ltd Opp S.D.M Ayurveda College,

Thanneerhalla B.M Road, Hassan 573201

Phone-off: 08172-257100

Sales: 9740140007

Service: 9902460005

E-mail: srihonda_hassan@yahoo.co.in

Website: www.srihonda.com

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SERVICE OF TWO-WHEELR (ACTIVA) AT SRI HONDA HAASAN
CHAPTER 3

MOTORCYCLE SERVICE

3.1 Motor Cycle Service Rules

1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that
do not meet Honda's design specifications may cause damage to the scooter.

2. Use the special tools designed for this product to avoid damage and incorrect assembly.

3. Use only metric tools when servicing the scooter. Metric bolts, nuts and screws are not
interchangeable with English fasteners.

4. Install new gaskets, O-rings, cotter pins, and lock plates when reassembling.

5. When tightening bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the
specified torque diagonally in incremental steps unless a particular sequence is specified

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3.2 Different Stages of Services

 Inspection: A technician will inspect your bike to identify any issues that need attention, such as
worn-out parts or damaged components. The inspection process may involve several steps, including

Figure 3.1 Inspection

 Visual Inspection: This step involves checking the overall condition of the bike, looking for any
signs of damage or wear and tear, and identifying any parts that may need repair or replacement.

Figure3.2Visual Inspection

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 Tires and Wheels Inspection: This step involves checking the tire pressure, the condition of the
tire treads, and the condition of the wheels to ensure that they are balanced and aligned.

Figure 3.3Tires Inspection

 Brake Inspection: This step involves checking the condition of the brake pads and the brake
cables, ensuring that the brake system is working properly and efficiently.

Figure3.4 Brake Inspection

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 Chain Inspection: This step involves checking the condition of the chain and making sure it is
clean and lubricated.

Figure3. 5 Chain Inspections

 Gear Inspection: This step involves checking the shifting mechanism, making sure the gears are
shifting smoothly, and adjusting them if necessary.

Figure 3.6 Gear Inspections

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 Frame Inspection: This step involves checking the condition of the bike frame, making sure there
are no cracks or damage that could affect the structural integrity of the bike.

Figure 3.7 Frame Inspections

 Cleaning: The bike will be thoroughly cleaned to remove dirt, grease, and debris, which will make
it easier to identify any problems and also improve the overall appearance of the bike.

Figure 3.8 Cleaning

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 Lubrication: The technician will apply lubricant to various parts of the bike, such as the chain and
gears, to ensure that they operate smoothly.

Figure3.9 Lubrication

3.3 Different Steps of Lubrication


 Select the appropriate lubricant: Choose the correct lubricant based on the manufacturer's
recommendations and the vehicle's specifications.

 Clean the vehicle: Before applying any lubricant, make sure the vehicle is clean, and there is no dirt
or debris that could mix with the lubricant.

 Apply lubricant to moving parts: Use a clean cloth or applicator to apply the lubricant to moving
parts, such as door hinges, window tracks, and hood latches.

 Do not over-apply: Apply the lubricant in moderation, as over-applying can cause it to accumulate
and attract dirt and debris, which could cause damage to the moving parts.

 Wipe off any excess: After applying the lubricant, use a clean cloth to wipe off any excess to prevent
it from getting on the vehicle's exterior or interior surfaces.

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 Inspect regularly: Regularly inspect the moving parts to ensure they are functioning correctly and to
identify any issues that may require further attention.

 Adjustment: The technician will adjust various components of the bike, such as the brakes, gears,
and saddle, to ensure that they are functioning correctly.

 Brakes: The brake pads and calipers may need adjusting to ensure that the brakes are working
correctly and effectively. The brake cables may also need adjusting to ensure that the brakes are
engaging and releasing smoothly.

Figure 3.10 Brakes

 Gears: The gear shifters and derailleur’s may need adjusting to ensure that the bike is shifting
smoothly and accurately. This can involve adjusting cable tension, limit screws, and derailleur
alignment.

Figure 3.11 Gears

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 Wheels: The wheels may need adjusting to ensure that they are true (not wobbling) and that the
spokes are tightened appropriately. This can improve the bike's stability and handling.

Figure 3.12 Wheels

 Handlebars and stem: The handlebars and stem may need adjusting to ensure that they are properly
aligned and tightened. This can improve the bike's steering and handling.

Figure 3.13 Handle

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 Seat and seatpost: The seat and seat post may need adjusting to ensure that they are at the correct
height and angle for your riding style and comfort.

Figure 3.14 Seat

 Replacement of Parts

Bike service that involves replacing parts is an important aspect of maintaining the functionality and safety
of a bike. Over time, parts of a bike can wear down or become damaged, and replacing these parts is
essential for keeping the bike in good condition.

Some common bike parts that may need to be replaced during a service include:

 Brake pads: These wear down over time and need to be replaced to maintain proper braking
performance.

Figure 3.15 Brake Pads

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 Chain: The chain can become stretched or damaged, and a worn chain can lead to further damage to
the bike's drivetrain.

Figure 3.16 Chain

 Tires: Worn or damaged tires can affect the bike's handling and increase the risk of a flat tire.

Figure 3.17 Tires

 Cables: These can become frayed or stretched, affecting the bike's shifting and braking performance.

 Bottom bracket: Over time, the bearings in the bottom bracket can wear down, leading to a noisy or
rough ride.

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SERVICE OF TWO-WHEELR (ACTIVA) AT SRI HONDA HAASAN
When taking a bike in for service, it's important to communicate with the mechanic about any issues you've
noticed and to ask questions about the recommended replacement parts. A good mechanic should be able to
provide an estimate for the cost of the service and a timeline for completing the work. It's also important to
follow up with regular maintenance to keep the bike in good condition and prevent future issues.

 Test ride: Finally, the technician will take your bike for a test ride to ensure that it is functioning
correctly and to make any final adjustments as necessary.

Figure 3.18 Test Ride

3.4 General Service

 Air Cleaner
• The viscous paper element type air cleaner can-not be cleaned because the element
contains a dust adhesive.
• If the scooter is used in unusually wet or dusty areas, more frequent inspections are
required. Remove the left side body cover. Remove the seven screws and air cleaner
housing cover.

Figure 3.19 Air Cleaner

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SERVICE OF TWO-WHEELR (ACTIVA) AT SRI HONDA HAASAN

Remove the air cleaner holder from the air cleaner housing cover. Remove the screws and air cleaner
element. Replace the element in accordance with the mainte nance schedule or any time it is exces-sively
dirty or damaged. Clean the inside of the air cleaner housing and cover. Make sure the rubber seals in the
housing and cover are in position and in good condition. Install a new element to the holder, and tighten the
screws.

Figure3.20 (b) Air Cleaner

Figure 3.20 (a) Air Cleaner

 Oil Change
Support the scooter with its center stand. Start the engine, warm it up and stop it. Remove the oil filler
cap/dipstick. Place an oil drain pan under the engine to collect the oil, then remove the engine oil drain
bolt and seal-ing washer. After draining the oil completely, install the new sealing washer and drain
bolt. Tighten the drain bolt to the specified torque.

Figure 3.21 (a) Dry Bolt Figure 3.21 (b) Oil changes

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SERVICE OF TWO-WHEELR (ACTIVA) AT SRI HONDA HAASAN

 Engine Oil Strainer Screen


Drain the engine oil. Remove the engine oil strainer screen cap, O-ring, spring. Remove
the engine oil strainer screen.

Wash the strainer screen thoroughly in non-flam-mable or high flash point cleaning
solvent until all accumulated dirt has been removed.

Blow it dry with compressed air to clean completely. Before installing the strainer screen, it
should be examined closely for damage and make sure the sealing rubber is in good condition.

Make sure the O-ring is in good condition and replace it if necessary. Install the engine oil
strainer screen and spring with the strainer sealing rubber facing the crankcase.

Coat the O-ring with engine oil and install the engine oil strainer screen cap. Tighten the engine
oil strainer screen cap to the specified torque.

Fill the crankcase with recommended engine oil and check the engine oil level. Make sure that
there are no oil leaks.

Figure 3.22 Oil Strainer Screen Cap

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 Left Crankcase Cover


Loosen the band screw and disconnect the air duct from the left crankcase cover

Figure 3.23 Crankcase Cover

 Remove the bolts, brake cable holder and left crank-case cover.

Figure 3.24 Bolts

 Remove the two dowel pins and cover gasket from the left crankcase.
Clean the gasket mating surface.

Figure 3.25 Gasket

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 Drive Belt
Removal/Installation
• The drive belt can be serviced with the engine installed in the frame.
Remove the following:
– Drive pulley face .
– Clutch/driven pulley.
 Remove the drive belt and replace it if necessary.
Install the following:
– Clutch/driven pulley.
– Drive pulley face.
– Left crankcase cover.

Figure 3.26 Drive Belt

 Drive Pulley
Remove the starter pinion. Remove the air cleaner housing bolts.

Figure 3.27 Drive pulley

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 Set the special tool lifting the air cleaner housing.


Hold the drive pulley face with special tool and loosen the drive pulley face nut.
Tools
Clutch center holder Remove the following:
– Nut
– Drive face flange
– Drive face fin
– Drive pulley face.

Figure 3.28 Clutch

 Slide the drive belt off from the drive pulley boss by squeezing the drive belt.

Figure3.29 Pulley

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 Remove the movable drive face assembly while holding the back of the face (ramp
plate) and drive face boss.

Figure 3.40 Drive face

3.5 Final Inspection of Two-Wheeler

Firstly, you should check the service schedule of your two-wheeler to see if it's time for a final service. This
typically involves a comprehensive check-up and maintenance of your vehicle to ensure it is in top condition.

Figure 3.41 First Inspection

Next, you should identify a reputable and authorized showroom for your two-wheeler brand, and book an
appointment for the service. It's a good idea to ask for an estimate of the cost of the service beforehand, so you
can plan accordingly.

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SERVICE OF TWO-WHEELR (ACTIVA) AT SRI HONDA HAASAN
On the day of the service, make sure to arrive on time and provide all the necessary documents related to your
vehicle, such as the registration certificate, insurance documents, and service records. It's also a good idea to
communicate any specific issues or concerns you may have with your two-wheeler, so the service team can
address them appropriately.

During the service, the showroom's technicians will inspect your two-wheeler, replace any worn-out parts, and
carry out any necessary repairs. Once the service is complete, they will also provide you with a detailed report
of the work done, along with any recommendations for future maintenance.

Finally, before taking your two-wheeler back home, make sure to test ride it to ensure everything is in
working order. If you notice any issues or have any questions, don't hesitate to ask the service team for
clarification.

Figure 3.42 Final inspection

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KNOWLEDGE GAIN AFTER INTERNSHIP

 Learnt different stages of services

 Learnt about general service

 Learnt final inspection of two-wheeler

 Learnt about different condition service for minor problems

 Learnt about small repair things

 Learnt about safety procedure

DEPARTMENT OF MECHANICAL ENGINEERING GECM, Page 31

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