GET TRAINING

EVALUATION
(VEHICLE QUALITY
SC)
HMSI VEHICLE QUALITY SC

TRAINING SCHEDULE
S.No Activity SEP'10 OCT'10

27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1 Introduction                                                      

2 VQ On                                                    

3 Conveyor Inspection                                                    

4 Re- Inspection & PDI                                                      

5 BOP Repair                                                      

6 Dismantling of Frame                                                    

7 Dismantling of Engine                                                    

8 Presentation                                                      
HMSI VEHICLE QUALITY SC

Shop Floor Layout

LOGISTIC
L1 L2 L3 L4

BRAKE 
TEST
SPEEDO
METER
ACCELERATION
TEST PD
I
R1 R2 R3 R4
VQ
VQ ON VQ OFF
ON
L1 L2 L3 L4

BRAKE  SPEEDO ACCELERATION

TEST METER TEST

R1 R2 R3 R4
REPAIR

CARD
REST IPP
MISS
AREA VEHICLE
VEHICLE
HMSI VEHICLE QUALITY SC

Connecting both
Verification of Verification of Frame  Checking of Brake &  Positive & Negative
Engine number   number Throttle Free play terminals of battery

Vmax & acceleration Speedometer Test to
Measuring front and Checking of Engine 
test for checking check speedometer
rear brake forces Noise
maximum speed error & needle vibration
HMSI VEHICLE QUALITY SC

1. All ways first connect the positive terminal of battery to 
the vehicle.
2.  Self start should be checked with both brakes.
3. Needle vibration should be in limit.
4. Headlight should be within high and low limit.
5. Choke lever must be closed while doing the Vmax test.
HMSI VEHICLE QUALITY SC

 Learnt the procedure of Initial 
TARGET Inspection being performed to check the 
vehicle for brake force, speedometer 
and acceleration.
 Achievement of the cycle time, and 
the target of 80 vehicles per day. 
Learnt about the different types of 
Engine Noise. 

DATE
HMSI VEHICLE QUALITY SC

If we tight the nut of front Brake by 15mm 
and each front and rear combi brake by 
10mm, then there will not be a problem of 
Brake Free play in 90% of vehicle.
HMSI VEHICLE QUALITY SC
HMSI VEHICLE QUALITY SC
• L Box Bolts  • Pillion step Cover • FC & FCC, Grommet • Fork Play
• Rear Grip • L-Cover • Frt Fork Arm , FLP • Frt wheel Heavy
• BDC Sticker • Kick Arm • Frt Cable Routing • Chk all stn stamp 
• Mole • Unloading

L1 L2 L3 L4

R1 R2 R3 R4

• Electical 
• IGN offset • FHC, • L- Hook
• Handle lock op •Winker  App • BDC, CC, Mole • Color verification
• Frt Fork  • BDC sticker • Main stand pin & 
• Pivot Cover • BDC- RCC gap Washer
• FC, FCC • Muffler , RR wheel Nut
HMSI VEHICLE QUALITY SC

Changes in the design of conveyor fixture.
1. Associate find difficulty to  put 
vehicle on stand over conveyor.
2.  Fixture does not provide tight 
grip to the vehicle.
HMSI VEHICLE QUALITY SC
HMSI VEHICLE QUALITY SC

S.No Defects Possible Solution

1. Head Light N/W 1. Check switch assembly.
2. Check the bulb.
3. Check the ACG Connection.
4. Check the tail light bulb some times it
get shortened and break the fuse.
2. Winker not working 1. Change the bulb
2. Change the winker cum relay

3. Self Start N/W 1. Check Self switch connection.

2. Check Bulb should not be Short.
3. Check Starter motor connection .
4. Check ACG connection.
4. Self Start Continue 1. Check Starter relay
2. Check connection of key set coupler.
HMSI VEHICLE QUALITY SC

DISMANTLING OF FRAME

DISMANTLE DISMANTLE DISMANTLE DISMANTLE

BDC FLP FCC & FC IC

DISMANTLE DISMANTLE DISMANTLE DISMANTLE

FT FORK BATTERY BOX FHC & RHC
•REMOVE ALL THE ELECTRICAL COUPLERS WHILE DISMANTLING & REMOVE 
THE HANGER BOLT TO REMOVE ENGINE FROM FRAME.
•ASSEMBLED BACK THE VEHICLE IN REVERSE ORDER.
HMSI VEHICLE QUALITY SC

 Ensure that Upper race cone and Lock nut should be 
tightened carefully with a torque wrench of 600 kgf-m.
  If it is loose it will result in fork 
play.

  If it is tight it will make the      
handle too hard to rotate.
 Ensure that there must be

• 26 balls in upper race Cone
• 19 balls in lower race cone
HMSI VEHICLE QUALITY SC
DISMANTLING OF ENGINE

REMOVE SEPARATE FRAME AND DISMANTLE MUFFLER DISMANTLE SELF MOTOR

WIREHARNESS ENGINE & CARBURETOR

DISMANTLE HEAD DISMANTLE CLUTCH & BELT DISMANTLE L CASE COVER DISMANTLE FAN & ACG
CVR,HEAD AND BLOCK

DISMANTLE L CASE DISMANTLE MISSION CASE DISMANTLE MISSION GEARS

HMSI VEHICLE QUALITY SC
HMSI VEHICLE QUALITY SC
HMSI VEHICLE QUALITY SC