Sri Lanka NVQ L3 Motorcycle Mechanic study plan

Label the main components of a four-stroke motorcycle engine on a stripped-down practice unit and state the function of each in one sentence

Explain the four-stroke cycle (intake, compression, power, exhaust) and identify which valve events occur at each piston position

Measure cylinder bore with a bore gauge and piston diameter with a micrometer, then calculate piston-to-cylinder clearance and compare it to the manufacturer's service limit

Use a feeler gauge and straight edge to check cylinder head and cylinder block warp, and record the readings against the limit

Identify and correctly name at least ten hand tools and measuring instruments used in engine work, stating the safety rule for each

Disassemble a practice engine in the correct sequence, tagging and bagging fasteners and recording the order in a log

Inspect and assess the condition of the piston, rings, ring grooves, gudgeon pin, and connecting rod small-end for wear and damage

Measure ring end gap and ring side clearance in the bore and decide whether the rings can be reused

Check valve stem-to-guide clearance and valve seat condition, then describe the lapping or replacement decision

Apply workshop safety rules during the teardown: PPE, correct lifting posture, solvent handling, and safe support of the engine on the bench

Reassemble the practice engine to the correct torque values and sequence, using a calibrated torque wrench and recording every fastener

Set valve clearance on a cold engine to specification and verify with a feeler gauge at the correct piston position

Time the camshaft to the crankshaft using timing marks and confirm correct alignment before and after rotating the engine twice

Describe how a carburettor meters fuel through the pilot, needle, and main circuits, and identify the mixture screw and idle speed screw on a real unit

Explain the function of the air filter, intake tract, and exhaust system, and state how a blocked filter or restricted exhaust changes mixture and performance

Adjust carburettor idle speed and mixture on a running practice engine to achieve a stable, smooth idle within the specified rpm range

Diagnose a rich and a lean running condition from spark plug colour, exhaust note, and throttle response, and state the corrective adjustment for each

Test ignition system components: measure coil primary and secondary resistance, check the spark plug gap and cap, and verify a strong blue spark

Set ignition timing to specification using a timing light or timing marks and confirm it stays correct when the engine is revved

Change engine oil and filter, check oil pump operation and oil flow to the head, and inspect the cooling system for coolant level, leaks, and fan or pump operation

Remove, inspect, and refit a clutch assembly, measuring clutch plate thickness and spring free length against limits

Adjust clutch cable free play to specification and explain the symptoms of a slipping and a dragging clutch

Remove and refit a chain and sprocket set, measure chain slack and sprocket wear, and state the correct adjustment and lubrication procedure

Inspect brake pads, discs, and drums, measure pad thickness and disc runout, and bleed a hydraulic brake system to a firm lever

Check steering head bearings for play and notchiness, inspect front fork seals for leaks, and measure rear suspension free play

Remove and refit a front and rear wheel, check wheel bearing play, and inspect tyre tread depth, pressure, and sidewall condition against legal and manufacturer limits

Check wheel alignment and balance status, and explain the handling symptoms of a misaligned or unbalanced wheel

Test a battery with a multimeter and hydrometer where applicable, and perform a charging system check on a running engine

Trace and repair a simulated lighting or indicator fault using a wiring diagram, a multimeter, and continuity testing

Test the starter circuit and describe safe jump-starting and battery charging procedures, including correct terminal polarity

Diagnose three given or simulated faults from symptom to confirmed root cause using a structured check sequence, and record the reasoning for each

Carry out a full periodic service on one motorcycle following a checklist: fluids, filters, fasteners, cables, brakes, tyres, lights, and battery

Remove and refit body panels, seat, and fuel tank, checking frame condition, mounts, and fastener condition on reassembly

Perform a pre-delivery and post-repair quality check: verify torque marks, fluid levels, light operation, brake function, and a short road or bench test

Write a customer-facing job card and explanation for one repair, stating the fault, the work done, and the parts replaced

Revise every domain using short self-made summary sheets, one page per domain, covering key limits, procedures, and safety rules

Re-measure and re-check five weak areas identified in earlier weeks, aiming to hit specification on every attempt

Complete a timed mock theory paper covering all ten domains and review every wrong answer to its source

Practise explaining three common repair procedures aloud as you would to an assessor, keeping safety points explicit

Prepare a tidy portfolio of all weekly deliverables with a contents page for final review