Project Report

Manik Sharma UE6936

About The Workshop

Working in the workshop in true sense was a dream come true. From the day I got to know about the training schedule, I never thought of going into a multinational company rather had a strong conscience of working at a place where I would be comfortable, involved and share thoughts among the most knowledgeable and practical crowd. The workshop mainly deals with all the possible light weight automobiles around us- from cars to motorbikes, from vintage to super sport. But the workshop is known for its expertise in Yamaha enginesmay it be Yamaha R1, the 1000cc engine or may it be Yamaha RD 350, a masterpiece in its own right, is what the workshop known for. The workshop is owned by Mr. Ashwini Rana under whose guidance and surveillance we got to know about the basics of engines. The workshop is centrally located in Gurgaon with the availability of most modern and up to the mark technology.

Goodwill Motor works

The workshop is in collaboration with GULF oils. Mr.Ashwini Rana has been working in this field for the last 15 years. Before opening the workshop he was a professional racer in the Indian and Dubai circuits. He raced for: Team Sherriff sponsored by Saudi Airlines Team Libra sponsored by Yamaha [Escorts, Haryana] Team Techtrack sponsored by Studds and MRF.

RECOVERING AND OVERHAULING OF YAMAHA RD 350

ABOUT YAMAHA 350

The RD350 was a motorcycle produced by Yamaha. It was the premier sport lightweight of the early 70's and was evolved from the piston port (pre-reed valve intake tract), front drum-braked, 5 speed Yamaha 350 cc "R5". Well developed for its time, it featured a reliable air-cooled, parallel twin, 6 speed (in some markets, such as the UK, the first model was sold in 5-speed form), reed valve equipped intake tract two-stroke engine. It was in production as a brandy red with white and black side details with metal emblem "Yamaha" on the tank RD350 (1973), the RD350A (1974), simple purple tank with "Yamaha" decal on the tank, and the orange with white RD350B (1975). The B model (in the UK at least) also featured a silver and black color scheme. All models were equipped with "Auto lube" automatic oil injection, relieving the user from the need to be mixing gasoline and two-stroke oil.

Rim sizes were 18" WM2 (1.85") front and 18" WM3 (2.15"), both being of chromed, wire spoked steel construction. In the UK, rim sizes were 1.60 front and 1.85 rear. Brakes were: single front disc brake and a rear drum brake, which Cycle Magazine described the combination as the best in its class. . The RD350B was assembled in India between 1983-1990 by Escorts Group under the brand name Rajdoot 350. It did not repeat the worldwide success of the RD350B in the Indian market. High purchase price and poor fuel consumption can be attributed to its lackluster sales figures. However, it established Yamaha as a performance bike manufacturer in India. There were two models for the Rajdoot 350 High Torque and Low Torque. Compared to the Yamaha RD350B that made 39 crankshaft bhp, the Indian-made HIGH TORQUE made 30.5 bhp and the later LOW TORQUE made only 27 bhp, all in quest of better fuel economy. By the time the production ended in 1990, the bike was completely indigenized with very little Japanese part content.

PROCESS OVERVIEW
For Body:
1. The chassis is carefully observed for any defects such as dents, scratches and bending. It is treated and painted as shown. 2. Denting of tank is properly done which is send for painting. 3. Denting of silencer and mud guards is done and is send for chroming. 4. The other body parts send for chroming are: rims, spokes, handle bar, nut, bolts and washers. 5. Buffing is the other process used for parts such as: rear and front hub, hub plates, shocker legs and head. 6. Zinc process is done for arts such as: axles, half axles, axle bots, axle nuts, spacers etc.

For Engine:
1.Proper cleaning of the engine case is done using brush, thinner, and diesel. It is to be made sure that if two engines are cleaned together, then the cases are not supposed to be mixed and kept according to their serial no. as marked on them. 2. Crank Rebuilding: The crank rebuilding is done on the lathe machine. It is rebuilt and balanced using new connecting rods and bearings. 3.Cylinder Reboring: this is done using a new oversized piston. The difference in the diameter of the initial and final piston has to be not more than 0.25 mm. 4. Gearbox: The gear box is carefully examined and gears are replaced if their teeth are damaged. Also selectors and counters are replaced if required.

Clutch:
1.Housing of the clutch is checked for defects and send for repairs if necessary. 2.Clutch Plates and Pressure Plates are carefully inspected for any sort of defects. These plates are used for better pick up and proper gear shifting to take place. For better performance, most of the times clutch is replaced witch gives higher torque. 3. The electrical points and cams are also worked upon or replaced if necessary 4. The rims are send for assembly after being chromed. 5. The front shockers are reassembled and put on to the frame and hence the tyres are fixed.

Carburetor
Carburetor, is a device that blends air and fuel for an internal combustion engine. In RD 350, two parallel twin engines are attached with two different carburetor. 1. The carburetor is opened and the air mixture screw, idling screw, main jet, pilot jet, main jet holder are removed. 2. They along with the housing are thoroughly cleaned with the help of diesel. 3. Reassembling is done and the float height is checked by either replacing or non replacing of float pin. Checklist if the bike does not start: 1. Check all the connections. 2. Check oil and electrical points. 3. Check the condensers.

IMPORTANT PROCESSES

BUFFING
Metal polishing, also termed buffing, is the process of smoothing metals and alloys and polishing to a satin, bright, or smooth mirrorlike finish. This is achieved by use of abrasives pads, belts and/or wheels with polishing compounds selected so as to achieve the desired effect. The use of abrasives in metal polishing results in what is considered a "mechanical finish". Metal polishing is often used to enhance cars, motorbikes, handrail, architectural metal applications, etc. Many medical instruments are also polished to prevent contamination in marks in the metals. All metal will oxidize over time. The removal of oxidization (tarnish) from metal objects is accomplished using a metal polish or tarnish remover; this is also called polishing. To prevent further unwanted oxidization, polished metal surfaces may be coated with a wax, oil or lacquer. This is of particular concern for copper alloy products such as brass and bronze.

Generally buffing is a multistage process. First, abrasives -which may be coated, non woven or woven -- are applied at high speed to remove surface defects like pits, nicks, lines and scratches from the articles to be buffed. Then mops of various materials are used to smooth the surface to be buffed. Lastly, cotton mops are used to give a mirror-like finish to the articles. As a general rule, coarse grit abrasives are used first and fine grit abrasives later. This gives a smooth finish by forming very thin lines that are not visible to the naked eye. Lubricants like wax, diesel fuel and kerosene are used as lubricating and cooling media during these operations. Sophisticated computer-controlled machines are available which do buffing of intricately shaped articles. Before the advent of such machines, buffing was done by hand. When polishing brass, there are often minute marks in the metal caused by impurities. To overcome this, the surface is polished with a very fine (600) grit tape, copper plated, then buffed to a mirror finish with a special cotton mop (called an airflow mop). Care must be taken when using these mops, as injury may result from the object being pulled out of the polisher's hands.

CHROMING
Chrome plating, often referred to simply as chrome, is a technique of electroplating a thin layer of chromium onto a metal object. The chromed layer can be decorative, provide corrosion resistance, or increase surface hardness. The component will generally go through these different stages. Degreasing to remove heavy soiling. Manual cleaning to remove all residual traces of dirt and surface impurities. Various pretreatments depending on the substrate. Placed into the chrome plating vat and allowed to warm to solution temperature. Plating current applied and component is left for the required time to attain thickness.

There are many variations to this process depending on the type of substrate being plated upon. Different etching solutions are used for different substrates. Hydrochloric, hydrofluoric, and sulfuric acids can be used. Ferric chloride is also popular for the etching of Nimonic alloys. Sometimes the component will enter the chrome plating vat electrically live. Sometimes the component will have a conforming anode either made from lead/tin or platinized titanium. A typical hard chrome vat will plate at about 25 micrometers (0.00098 in) per hour. Formerly most decorative items affixed to cars were referred to as "chrome", by which phrase was actually meant steel that had undergone several plating processes to endure the temperature changes and weather that a car was subject to outdoors. The most expensive and durable process involved plating the steel first with copper, and then nickel, before the chromium plating was applied.