ITI/NCVT Mechanic Motorcycle (AITT Theory) study plan

Sketch and label the four-stroke cycle (intake, compression, power, exhaust) for a single-cylinder motorcycle engine, naming valve positions and piston direction at each stroke

Identify on a real or schematic engine the cylinder block, cylinder head, piston, rings, gudgeon pin, connecting rod, crankshaft, camshaft and valve train, and state the function of each

State the firing order and working principle of a single-cylinder four-stroke versus a two-stroke engine, including transfer and exhaust port timing

List the personal protective equipment and machine-guarding rules that apply when working on a running or partially dismantled engine, and explain the risks of rotating parts, hot exhaust and fuel vapour

Demonstrate the correct procedure for safely isolating an engine before inspection (fuel tap off, battery disconnected, engine cool) and record the steps in writing

Explain valve timing events (valve opening and closing relative to top dead centre and bottom dead centre) and describe how cam profile and cam chain or pushrod arrangement produce them

Describe combustion chamber types used on motorcycles and explain the effect of compression ratio on power and detonation

Use a vernier caliper, micrometer and dial gauge to measure cylinder bore, piston diameter and crankshaft runout, and record readings to 0.01 mm

Calculate piston-to-bore clearance and cylinder taper from your measurements and compare results with a typical service specification

Explain the purpose of a feeler gauge, torque wrench and plastigauge, and demonstrate correct torque-wrench use and setting

Trace the fuel path from tank through tap, filter, carburettor or fuel-injection throttle body to the combustion chamber, and name the function of each component

Explain carburettor circuits (float, pilot, needle-jet, main) and the air-fuel ratio range for idle, cruise and full throttle

Describe the magneto and battery-coil ignition systems, including the role of the contact breaker or electronic trigger, condenser or capacitor, ignition coil and spark plug, and state typical spark plug gap

Identify the properties and correct application of engine oil grades (viscosity rating and API or JASO classification) and explain wet-sump versus dry-sump lubrication and oil pump operation

Classify common engineering materials used on motorcycles (cast iron, aluminium alloy, steel, rubber) and select the correct fastener grade and thread type for a given joint

Explain air cooling and liquid cooling systems, including fins, radiator, thermostat, water pump and coolant flow, and state the symptoms of overheating

Diagnose a rich and a lean mixture from spark plug colour and exhaust symptoms, and state the corrective adjustment

Describe the function and operation of a wet multi-plate clutch, and explain clutch slip, drag and judder causes

Explain the construction and ratio calculation of a constant-mesh gearbox and the role of the shift drum and forks

Describe chain, belt and shaft final drive, including chain slack adjustment, sprocket wear inspection and shaft-drive bevel gear basics

Trace power flow from crankshaft through clutch, gearbox and final drive to the rear wheel, and identify where each component sits in the drive train

Explain the purpose of the frame, and compare tubular, cradle and perimeter frame types with their advantages

Describe telescopic front fork construction (stanchions, springs, damper rod, oil) and rear suspension types (twin shock, monoshock, swingarm linkage), including preload and damping adjustment

Explain steering geometry terms: rake angle, trail, wheelbase and steering-head bearings, and state the effect of incorrect trail on handling

Describe wheel construction (spoked and cast), tyre removal and refitting, and wheel balancing principles

Explain the operation of drum and disc brakes, including master cylinder, caliper, pads and brake fluid, and state the cause of brake fade and spongy lever feel

Describe the procedure for bleeding a hydraulic brake system and for adjusting a drum brake and cable free play

Read a tyre sidewall and interpret size code, load index, speed rating, construction and DOT date code

Explain tyre wear patterns (centre wear, edge wear, cupping, flat spotting) and relate them to pressure, alignment and suspension faults

Describe wheel alignment checks on a motorcycle, including rear-wheel alignment to the front and the effect of misalignment on tyre wear and handling

Explain battery construction, lead-acid versus lithium-ion types, capacity rating in ampere-hours, cold cranking amps, and the correct charging procedure and safety precautions

Trace the charging circuit (stator, regulator-rectifier, battery) and the starting circuit (battery, starter relay, starter motor, switches), and describe how to test each with a multimeter

Describe the motorcycle wiring harness, earth return, fuse protection and the function of the main switch, lighting and indicator circuits

Explain the role of the engine control unit and common sensors (crank position, throttle position, oxygen, temperature) in an electronic fuel-injection system

Apply a structured diagnostic sequence (verify complaint, gather symptoms, test in order, confirm repair) to a no-start and a no-charge fault, and list the multimeter readings expected at each step

Explain fits and tolerances (clearance, interference, transition) and interpret a basic hole-basis fit designation from a workshop drawing

Describe thread forms, thread pitch measurement and the correct use of taps, dies and torque sequences for cylinder-head bolts

Perform a full periodic service sequence on a motorcycle: oil and filter change, air filter, spark plug, chain adjustment and lubrication, cable adjustment, brake check and fastener torque check

Prepare a maintenance schedule table linking service interval to the checks required at that interval

Complete a full-length mock examination across all ten domains under timed conditions and review every incorrect answer