Maharashtra HSC Scooter & Motorcycle Servicing (Bifocal) study plan

Set up a safe work bay: state PPE, petrol storage, jacking and fire-extinguisher rules, and demonstrate correct lifting of a two-wheeler on a service stand.

Identify and correctly use 12 hand tools and 5 special tools (magneto puller, clutch nut spanner, valve spring compressor, bearing puller, chain rivet tool) on a scrap engine.

Measure cylinder bore, piston-to-bore clearance and crankshaft runout with a bore gauge, micrometer and dial gauge, and record each reading with its wear limit.

Sketch the four-stroke cycle and label intake, compression, power and exhaust events with valve opening and closing points for a 100-125 cc single-cylinder engine.

Strip and reassemble a single-cylinder air-cooled engine in the correct sequence, torquing the cylinder head and clutch nut to specification in the correct pattern.

Trace the full lubrication circuit from oil strainer through oil pump, centrifugal filter and galleries, and explain what happens to pressure when the strainer clogs.

Inspect and measure piston ring end gap, ring groove clearance and valve stem-to-guide clearance, then decide reuse or replacement for each part.

Diagnose three cooling and lubrication faults (oil starvation scoring, blocked fins, failed oil pump) from given symptoms and state the corrective action.

Disassemble, clean and reassemble a slide-type and a CV carburettor, identifying pilot jet, main jet, needle, float and air screw and their functions.

Perform idle-speed and air-screw adjustment on a running engine and explain the effect of one step richer or leaner on plug colour and exhaust note.

Test a fuel pump and injector circuit on an EFI two-wheeler and read sensor data such as TPS, MAP and engine temperature from a diagnostic scanner.

Explain how a catalytic converter and a closed-loop oxygen sensor work together, and list three causes of high CO in a Bharat Stage VI two-wheeler.

Trace an exhaust restriction fault from low power and hot exhaust back to a blocked muffler or collapsed inner pipe, and verify the repair by road test.

Test a battery with a hydrometer or load tester, then carry out constant-current and constant-voltage charging while stating the correct charging rate for a given Ah rating.

Measure charging-system output with a multimeter across the battery terminals at idle and at raised rpm, and diagnose a failed regulator-rectifier from the readings.

Trace a complete lighting and indicator circuit on a wiring diagram, then locate two injected faults with a multimeter within a set time limit.

Test an ignition coil, spark plug cap and CDI or TCI unit, and explain how a weak coil shows up as a misfire under load but not at idle.

Measure steering-head bearing play and adjust the steering stem nut, then verify free movement lock to lock without binding.

Check front fork oil level, seal leakage and rear shock absorber damping, and state the symptoms of worn bushes and a blown fork seal.

Measure wheel runout with a dial gauge, check spoke tension and rim offset, and decide whether a wheel needs truing or replacement.

Read tyre size, load index and speed symbol from a sidewall, measure tread depth, and state the legal and safe replacement point for a two-wheeler tyre.

Check wheel alignment and swingarm bush play on a running machine, then confirm the correction through a straight-line and hands-off road test at low speed.

Remove, inspect and refit a wet multi-plate clutch, measuring clutch spring free length and friction plate thickness against the service limit.

Explain the power flow through a constant-mesh gearbox in first and top gear, and identify the parts that turn when the gearbox is in neutral.

Diagnose a jumping-out-of-gear complaint by checking shift fork wear, drum detent and gear dogs, and state the repair for each cause.

Adjust drive chain slack to specification, measure chain stretch over a set number of links, and inspect sprocket tooth wear for hooking.

Inspect and adjust a CVT belt drive on a scooter, measuring belt width and roller weight wear, and describe the symptoms of a worn belt.

Bleed a hydraulic disc brake, replace fluid, measure pad thickness and disc runout, and verify lever feel against the specification.

Adjust a drum brake, set the brake pedal and lever free play, and test brake balance and stopping distance on a dry surface at 30 km/h.

Prepare a periodic maintenance schedule for 1,000, 5,000 and 10,000 km services, listing the inspection and replacement items for each interval.

Diagnose a non-starting engine using the fuel-spark-compression sequence and record the result of each test in order.

Write a job card and a customer handover note for one repair, covering complaint, cause, action, parts used and road-test result.

Perform a full pre-delivery inspection on a scooter or motorcycle and sign off every check on the checklist.

Run a structured road test covering cold start, acceleration, braking, steering and electrical functions, and record every abnormality noticed.

Re-solve one missed question from each earlier domain, writing the correct answer with the reasoning behind it.

Complete two timed full-length mock papers and review every error down to the underlying fact or procedure.