DEPARTMENT OF MECHANICAL ENGINEERING

BHARATI VIDYAPEETH COLLEGE OF ENGINEERING,

NAVI MUMBAI
A Report of Industrial Training
At,
ROYAL ENFIELD SERVICE CENTRE - RAM MOTORS
(From: 01-06-2022 To 11-06-2022)
Submitted By,
Saurabh Arun Patil
Sajan Harishchandra Patil
Azhar Izhar Shaikh
Saurabh Shidwa Parhyad
Ganesh Khanderao Sanap
Raj Pradeep Makare
Dhananjay Damodar Barde
Ayush Chandrashekhar Thakur
Suraj Ramachandran Nair
Saswat Rajani Sahoo

In partial fulfilment for the award of the degree

BACHELOR’S OF ENGINEERING
In
MECHANICAL ENGINEERING
 CERTIFICATE

Certified that this Report of Industrial Training at

ROYAL ENFIELD SERVICE CENTRE - RAM MOTORS

Being submitted here with to the

BHARATI VIDYAPEETH COLLEGE OF ENGINEERING

Is the bonafide work of

Who carried out the project work under our guidance and supervision.

Mr. Himanshu Singh Prof. Dilip Radkar Dr. Sandhya Jadhav Mr. Ashok Bhanage
Internship Guide Internship Coordinator Principal Manager

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 ACKNOWLEDGEMENT

I would like to express my special thanks and gratitude to Mr. Himanshu Singh
and Mr. Ashok Bhanage who gave me the opportunity to do this Industrial Training
at Royal Enfield Service Station-Ram Motors, where I got to enrich my skills and
learned a lot about mechanical aspects of a vehicle.

Date: 11-06-2022 Saurabh Arun Patil

Place: Ram Motors, Nerul Sajan Harishchandra Patil

Azhar Izhar Shaikh

Saurabh Shidwa Parhyad

Ganesh Khanderao Sanap

Raj Pradeep Makare

Dhananjay Damodar Barde

Ayush Chandrashekhar Thakur

Suraj Ramachandran Nair

Saswat Rajani Sahoo

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 PREFACE

From 01-06-2022 To 11-06-2022 (11 Days), We did an Internship at ROYAL

ENFIELD SERVICE CENTRE - RAM MOTORS, NERUL. Every Student of
Bachelor of Engineering in Mechanical Engineering has an essential requirement to
do part time or full time internship in any of the well reputed organization. The
purpose of this program is to acquaint the students with practical applications of
theoretical concepts taught to them during the conduction of their course. Really, it
was a nice opportunity to have a close comparison of theoretical concept in practical
field. The output of my internship is summarized in shape of the internship report.

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 TABLE OF CONTENTS

Sr. No. Title Page No.

1. Observations 5
2. Servicing Department 7
3. Skills Learned 10

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OBSERVATIONS
These are the series of points noted down by the members over the period of 11 days of our
internship at Royal Enfield Service Centre-Ram Motors.

Equipment:

It was observed that the workshop consisted in total of 11 ramps for the technicians to repair bikes
along with 2 vacant spaces for extra vehicles to be treated. All the ramps consisted of an air
connection which diverted into 2 parts namely the 'air spray' to clean the small spaces in the vehicle
and the 'gun' to tighten or loosen the big screws. Each of these 11 ramps had 3 compartments to
store all the equipment like wrenches of varying sizes used to repair the vehicle. There was also a
big oil barrel of 210 liters to fill in the oil during the service. The station has a parts shop from
where all the original parts of Royal Enfield were provided for the servicing of the vehicles. The
workshop also has a cleaning area for cleaning your vehicles completely.

Management:

When you first enter the station with your vehicle to get checked there are people to attend to your
problems. After checking your vehicle a 'job card' is created by the service consultant which is
then transferred to the Shop floor Manager where your vehicle will be going to diagnosed to which
the manger selects which vehicle to give to whom accordingly the major problem arise vehicle
goes to the senior technicians while the servicing of vehicles and other minor problems of the
vehicles goes to the junior technicians by the system according the issues are detected in the
vehicle. The team of technicians is led by their shop floor manager Himanshu Singh along with
Ram Gupta and the manager Ashok Bhanage who is always present at the station. No outsider
was to enter the working space of the shop floor allowed except the technicians and manager.
There was a waiting area for people who wish to wait until their vehicles were serviced completely.

Safety Protocols:

All the safety protocols were thoroughly followed by all the working staff at the station. It is
mandatory for all the technicians to wear work boots and their uniform. Same things were followed

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by all the interns working here as well. The workshop also has a good ventilation system. There
was always availability of first aid kits and fire extinguishers. As we had our internship during the
Covid the service station always had all the safety measures like sanitation which we thoroughly
followed.

Garbage control:

Garbage control was one of the main thing that was seriously looked after by the people, all the
waste parts or the parts that have to be changed were stored in big containers behind the work
station.
Also the waste oil or oil that has been changed was properly stored at backside of the workshop in
an oil drum.

Customer service:

The customer service was well looked after there are people to attend to your vehicle.
There is telephone service for you to book an appointment beforehand. If your vehicle has a service
due then they will contact you. Also, if your vehicle is not done by the time given to you, you will
get a free home delivery of the vehicle.

Worker skills:

All the technicians at the workshop were greatly skilled for treating the Royal Enfield vehicles.
They knew full particulars of their craft, be it basic servicing or handling the engine. Over the
period of time they taught us (interns) many things about the bike why a particular part is fitted
here or how it functions. Also why it is used. And cleared handsome amount of doubts.

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SERVICING DEPARTMENT

The first service is scheduled at 500 km or 6 months whoever comes earlier. The second and third
services are scheduled at 5000 km or 6 months and at 10000 km or next 6 months respectively
whichever comes earlier.

● Changing or Cleaning of Air filter

● Oil replacement
● Changing of oil filter
● Cleaning chains
● Wheel Alignment
● Checking defects in the sensors using tool kit
● Oiling

1. AIR FILTER

Air filter must be changed if it is fully damaged else it is cleaned with air pressure gun. The above
1st picture indicates the air filter in yellow, it is cleaned using the air pressure gun and later fitted
to its place shown in the 2nd image.

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 2. OIL REPLACEMENT

In its first service, replacement of the engine oil is done. The oil is supposed to be changed if it
acquires a darkish colour. This oil can prove harmful to the vehicle as it is burnt. Engine oil is
refilled in case it has been burnt up. We remove the old oil from the outlet and replace it with new
oil.

3. CLEANING CHAIN

Once the chain is adjusted neither tight nor loose. Chain need to be cleaned with chain cleaner in
order to prevent it from rusting. Periodic chain maintenance extends life of the chain set. The
motorcycle chain tends to stick dirt and slush on it, due to which efficiency is decreased.

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4. WHEEL ALIGNMENT

Wheel Alignment is main factor in the while running the bike. Checking whether the tires are
aligned properly or not, if not then tires alignment needs to be fixed.
The misaligned wheel is attached to the stand without the tube and rotated clockwise and
anticlockwise if there is any bend or curve on the wheel rim a marking is done on it then it on the
marked area it is hammered. Lubrication of bearings in tires is to be done.

5. CHECKING FOR ANY DEFECTS IN SENSORS

The sensors are required to be checked. Possible causes of failure:

 Breaks in wiring
 Internal short circuits
 External damage

6. OILING

Lubrication of every moving component is to done so that it can be work smoothly.

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SKILLS LEARNED DURING INTERNSHIP

1. How Clutch Plate Works

When the clutch lever is pressed, the action causes the compressed springs on the pressure plate to
retract. Resulting in power getting transmitted to the gearbox and the vehicle is able to move. It
consists of 6 clutch plates and 5 pressure plates and it has constant mesh gear type.

2. What does “BS” stands for?

Bharat Stage (BS) is an emission standard which is laid down by the government to regulate the
output of air pollutants from engine and spark ignition engine equipment, including motor vehicles.

3. Siezing of an engine
An engine Seizure occurs when the engine overheats. All the metals in the engine tend to expand
and two such parts that are place with hairline gap between them are piston and engine wall. This
causes the both of them to expand and sometimes fuse together to form a weld, which blocks the
piston movement.

Causes:
1. Driving Conditions

2. Bike Service Quality

3. Engine Oil

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4. Oil filter

5. Coolant Level

Other Factors
There some of the other factors that play a minor role in causing engine to seize, although these
factors do not contribute much to engine seizure.

Tyre Pressure: Ride your motorcycle at right tyre pressure.

Overloading: Do not overload your motorcycle.

Preventing a Seized Engine

Here’s a basic list every motorcyclist should follow to avoid engine seizure.

1. Periodic Service
2. Periodic Oil and Oil Filter Replacements
3. Coolant top-up for liquid cooled engines
4. Not revving the engine too much to stress it
5. Quality Service

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7. GEAR BOX

Royal Enfield 5-speed gearbox will fit 4-speed bikes Right-shift five-speed will fit four-speed
Bullets. You can replace the four-speed transmission of your Royal Enfield motorcycle with
new Royal Enfield five-speed transmission.

8. DRUM BRAKE

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There is a Pair of Brake Shoe with the help of springs the mechanism works according once the
lever is pulled by the pedal i.e., once the brake is applied.

● Once mechanical push force is applied on the brake pedal through the actuating rod the
lever gets activated.
● Attached to it camshaft rotates
● The camshaft will be activating the actuator pin then the brake shoe will work
● As the pin gets rotated brake shoes get expanded.
● As result, the retaining spring gets expanded.
● The brake shoe will be pushed against the inner surface of the drum.
● Due to which brake lining on brake shoes will be in contact with the drum.
● The brake drum acts as a braking surface on the wheel side.
● The friction between the lining and the drum is what makes the wheels slow down.

9. DISC BRAKE

A disc brake is a type of brake that uses the calipers to squeeze pairs of pads against a disc or a
rotor to create friction. This action slows the rotation of a shaft, such as a vehicle axle, either to
reduce its rotational speed or to hold it stationary.

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GROUP PHOTO

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