INTERNSHIP I REPORT

GOVERNMENT POLYTECHNIC COLLEGE PERIYA

KASARAGOD

INTERNSHIP I REPORT

Internship report submitted in partial fulfillment of the

requirements for the award of
Diploma in Mechanical Engineering
Under State Board of Technical Education, Kerala

Submitted by,

ALAN NOBLE
Reg.No:2201020010

Department of Mechanical Engineering

Government Polytechnic College Periya Kasaragod

2023

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GOVERNMENT POLYTECHNIC COLLEGE

PERIYA KASARAGOD
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

Certified that the internship report is submitted by ALAN NOBLE bearing

Reg.No:2201020010 in partial fulfillment of the requirements for the award of Diploma in
Mechanical Engineering Under The State Board of Technical Education, Kerala during academic
year 2023-24. It is certified that all corrections/suggestions indicated for Internal Assessment have
been incorporated in the report deposited in the departmental library. The internship report has been
approved as it satisfies the academic requirements in respect of internship training for the said degree.

INTERNSHIP COORDINATOR HOD

Sri. GOPINATH P Sri. PRAJINLAL K P

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CERTIFICATE OF INTERNSHIP

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GOVERNMENT POLYTECHNIC COLLEGE KASARAGOD

Our Vision
To be an institute of global repute, moulding socially committed technicians and entrepreneurs
bringing sustainable development.

Our Mission
1. Provide value based quality technical education and training using state of the art
infrastructure, tools and methodologies.
2. Collaborate with industries and academic institutions, bridging the gap between curriculum
and latest industrial practices.
3. Promote co and extra- curricular activities, fostering leadership qualities, problem solving
skills and team spirit.
4. Create an ambience for career building, encourage life-long learning leading to self-actualization.

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DEPARTMENT OF MECHANICAL ENGINEERING

Vision

To Excel in mechanical engineering education moulding engineers and

entrepreneurs for the socio-economic upliftment of society.

Mission - To:

M1. Educate the students via state of art teaching-learning

process and Industry-Institute symbiosis.
M2. Enhance the leadership, innovation, and entrepreneurship
skills to make the students ready for industry.
M3. Enable the students to contribute for the development of
society, following universal human values.
M4. Encourage lifelong learning, consultancy, and
training for overall development.

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DEPARTMENT OF MECHANICAL ENGINEERING

PROGRAM EDUCATIONAL OBJECTIVES (PEOs)

To create engineers and entrepreneurs who will be able to:

PEO 1. Handle technological problems, provide unique

solutions, and satisfy customer needs.
PEO 2. Contribute to the emerging challenges faced by
industries and society following efficient
management practices.
PEO 3. Ethically stand for the well-being of the society and
the environment following universal human values.
PEO 4. Maintain a passion for updating, enriching, and sharing
knowledge.

PROGRAM SPECIFIC OUTCOMES (PSOs)

Students in the Mechanical Engineering Programme will be able to:

PSO 1. Apply the skills in operating advanced machine tools,

industrial maintenance, service and computerized
testing of IC engines.
PSO 2. Apply the skills for designing and
manufacturing innovative products using
modern CAD/CAM tools.
PSO 3. Apply entrepreneurship and management skills to
develop small - scale industry startups.

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DECLARATION

I, ALAN NOBLE [Reg. No.2201020010], student of III rd Semester Diploma in

Mechanical Engineering, Government Polytechnic College Periya Kasaragod hereby declare
that the internship report has been submitted by me in partial fulfillment of the requirements
for the award of Diploma in Mechanical Engineering Under The State Board of Technical
Education, Kerala during academic year 2023-2024.

DATE : NAME:ALAN NOBLE

PLACE :PERIYA REG. NO:2201020010

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ACKNOWLEDGEMENT

First I would like to thank Sri. .SAJEESH V, MANAGER,Aaaryan Motors kanhangad,

Indiranagar for giving me the opportunity to do an internship within the organization. I also would
like all the people that worked along with me at Aaaryan Motors kanhangad, , Indiranagar with their
patience and openness they created an enjoyable working environment.

I would like to express my thanks to the Principal Sri. NARAYANA NAIK P for the encouragement
that motivated me for the successful completion of internship work.

It gives me immense pleasure to thank Sri. PRAJINLAL K P, Lecturer and Head of

Department for his constant support and encouragement.

I would also like to thank the Internship Coordinator Sri. GOPINATH P, Lecturer,
Department of Mechanical Engineering and all other teaching and non-teaching staff of
Mechanical Engineering Department who has directly or indirectly helped me in the
completion of the internship work.

Last, but not the least, I would hereby acknowledge and thank my parents who have been a
source of inspiration and also instrumental in the successful completion of the internship
work.

NAME :ALAN NOBLE

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ABSTRACT

A aryan suzuki in kanhangad south, kasaragod is a top player in the category motorcycle
dealers suzuki in the kasaragod . This well-known establishment acts as a one stop
destination servicing customers both local and from other parts of kasaragod . Over the
course of its journey, this business has established a firm foothold in it’s industry .The belief
that customer satisfaction is as important as their products and services, have helped this
establishment garner a vast base of customers, which continues to grow by the day . This
business employs individuals that are dedicated towards their respective roles and put in a lot
of effort to achieve the common vision and larger goals of the company . In the near future,
this business aims to expand its line of products and services and cater to a larger client base
in kasaragod , this establishment occupies a prominent location in kanhangad south . It is an
effortless task in commuting to this establishment as there are various modes of transport
readily available . It is known to provide top service in the following categories :motorcycle
dealers, scooter dealers, motorcycle dealers.

The importance of vehicles is an issue that cannot be overemphasized as the daily routine of
most individuals entails the interaction with vehicles to go about businesses and move people
and goods from one place to another. This implies that with the breakdown of vehicles, our
live sand businesses tend to experience a noticeable amount of stress compared to what it was
before the breakdown. This brings up the issue and ultimately the business of automotive
maintenance and repair. With the possibility of a breakdown on one’s mind, the menacing
topic
of automotive maintenance cannot be taken with levity.

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TABLE OF CONTENT

1. Acknowledgements…………….
4

2. Abstract……………………….
5

3. Table of contents……………...
6

4. Internship objectives………... 7

5. Weekly overview of internship activities… 8

6. Introduction………………… 11

1.1Origin of the Report…... 11

1.2. History of Suzuki……. 11
1.3. Scope of Study..,……. 12

7. Company profile…………. 13

8. Internship Diary………… 14
3.1.Day wise activities………………. 14
3.2 Skills attained… …………….. 21

9. Recommendation & Conclusion……….. 22

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INTERNSHIP OBJECTIVES

Achieve knowledge in the practical field of an organization in order to make theoretical

knowledge to be more fruitful and realistic is called practical training or internship
.
 To make theoretical knowledge clear and exact.

 To increase the value of theoretical knowledge.

 To remove the limitations of theoretical knowledge.

 To get practical knowledge about the institution.

 For reporting practice.

 Identify the problems and put forward recommendations.

 To know about the present situation of the institutions.

 To expand the span of knowledge.

 To implement the knowledge of practical training in the practical life.

 To know how to solve managerial problems.

 To innovate new techniques of management.

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 To suggest some measures for the improvement of the profitability Position of an

organization.

WEEKLY OVERVIEW OF INTERNSHIP ACTIVITIES

DATE DAY NATURE OF WORK

15-05-2023 Monday Introduction of showroom

16-05-2023 Tuesday Introduction of tools and machines

17-05-2023 Wednesday To change Engine Oil and Oil Filter

WEEK 1

18-05-2023 Thursday To change Engine Oil and Oil Filter

19-05-2023 Friday Clutch plate change

20-05-2023 Saturday Air filter change

21-05-2023 Sunday Holiday

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DATE DAY NATURE OF WORK

22-05-2023 Monday Break pad change

23-05-2023 Tuesday Variator rollar cleaning

24-05-2023 Wednesday Front disk pad change

WEEK 2

25-05-2023 Thursday Battery accessories Change

26-05-2023 Friday Spark plug cleaning

27-05-2023 Saturday Front suspension change

28-05-2023 Sunday Holiday

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DATE DAY NATURE OF WORK

29-05-2023 Monday Silencer replace

30-05-2023 Tuesday Accident bike repair

31-05-2023 Wednesday Engine work

WEEK 3

01-06-2023 Thursday Engine work

02-06-2023 Friday Throttle body cleaning

03-06-2023 Saturday Timing chain repair

04-06-2023 Sunday Holiday

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CHAPTER 1
INTRODUCTION

1.1 Origin of the Report :

This internship report on “Automotive Technology and Maintenance & Servicing of Suzuki
motors Kanhangad ” is prepared to fulfill the partial requirement of then internship program
for the Diploma in Mechanical Engineering Under The State Board of Technical Education.
As a student of Mechanical Engineering, I had to complete a three weeks internship with any
organization. I was assigned in Aarnyan motors Kanhangad,

1.2 History of Suzuki :

Suzuki is a Japanese multinational corporation that has a rich history in manufacturing

motorcycles, automobiles, and other engines. It was founded by Michio Suzuki in 1909 as
Suzuki Loom Works, initially focusing on textile looms. In the 1930s, Suzuki diversified into
the production of small cars and motorcycles.

After World War II, Suzuki gained popularity with its motorcycles, particularly the Suzuki
Diamond Free. In the 1950s and 1960s, the company expanded globally, establishing itself as
a key player in the motorcycle market. In 1970, Suzuki entered the automobile market with
the launch of the Suzuki Jimny.

Over the years, Suzuki has been known for its innovation in lightweight and fuel-efficient
vehicles. The Suzuki Alto, introduced in the late 1970s, became a notable success. Suzuki’s
off-road vehicles, such as the Suzuki Samurai and later the Suzuki Vitara, also gained
popularity.

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In the motorcycle realm, Suzuki has a strong presence in various racing events, achieving
success in MotoGP and other competitions. The GSX-R series is particularly renowned for its
sportbikes.

Suzuki has faced challenges, including financial difficulties in the early 2000s. However, the
company has persevered and continued to produce a diverse range of vehicles, maintaining a
global presence.

1.3 Scope of Study:

The study would focus on the following areas of automobile.

 Its body and its structural design.

 Its powertrain and amount of performance it can deliver.

 Its automotive technology and its electrical features.

 Its maintenance and servicing system.

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CHAPTER 2
COMPANY PROFILE

Aaryan Motors Kanhangad South Junction

Aaryan Suzuki in Kasaragod is one of the leading businesses in the Motorcycle Dealers-
Suzuki. Also known for Motorcycle Dealers, Scooter Dealers, Motorcycle Dealers-Suzuki
(Authorised), Motorcycle Dealers-Suzuki, Motorcycle Dealers-Suzuki Hayabusa, Motorcycle
Dealers- Suzuki Bandit (Authorised), Motorcycle Dealers-Suzuki Bandit, Motorcycle
Dealers-Suzuki Gsx R1000 (Authorised)and much more. Find Address, Contact Number,
Reviews & Ratings, Photos,Maps Of Aaryan Suzuki, Kasaragod.

Suzuki has always operated under the value-packed product principle. The company is
entirely Committed to providing products that satisfy consumer demand by combining its
innovative,Long – cultivated technological edge with its young, vibrant workforce. If you
want to try a Suzuki Motorcycle, Motorcycle Dealers-Suzuki could help you with test drives.
Some dealers also Keep pre-owned bikes, which you can look for if you are looking for better
deals

Aaryan Suzuki in Kanhangad South, Kasaragod have maintained a solid footing in all areas
Related to providing a great motorcycle experience through its.

AARYAN MOTORS
Signature Motors Kasaragod Pvt Ltd.
Near Little Flower High School, Hosdurg,
Kanhangad, Kasaragod, Kerala, India
Pin Code – 671315

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signature@thebusinesshouse.org

CHAPTER 3
INTERNSHIP DIARY

3.1 Day Wise Activities:

3.1.1.Introduction of showroom.

3.1.2.Introduction of tools and machines.

 Screw Driver.
 Socket Accessories.
 Socket Sets.
 Reversible Ratcheting Spanner.
 Wire strippe.
 Ball peen Hammer
 Pliers.
 Mallet.
 Tire Pressure Gauge.
 Measuring Tape.

3.1.3.Engine Oil and Oil Filter Change

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 Access the drain plug and oil filter.

 Drain the oil.
 Remove the oil filter.
 Install a new oil filter.
 Reinstall the drain plug.
 Add new motorcycle oil.
 Run the engine and check for leaks.
 Properly dispose of the used oil and filter.

3.1.4.Clutch Plate Change

 Drain Any Oil Or coolant from the bike.

 Disconnect Clutch cable friction plates.
 Remove the clutch friction plates.
 Inspect the clutch basket for damage.
 Coat the friction plate in Oil and install.
 Reinstall the clutch cover and cable.
 Di pose the old oil and used clutch plates properly

3.1.5.Air Filter Change

 Locate your motorcycle’s air filter
 Choose the right type of air filter
 Install the new air filter

3.1.6.Brak Pad Change.

 Dismandle the brake pad from the wheel
 Remove the old brake pad
 Fit the new brake pad into the brake caliper
 Assemble the brake caliper into the wheel

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3.1.7.Variator Rollar Cleaning

First remove the air box,and then tie up the air box so that you can get at The bolts. Remove
the rubber sleeve. Hold the clutch and undo the nut of the rear Drive shaft. Loosen the
variomatics cover. You can now remove the variator cover.Do not lose the adapter sleeves of
the cover. Block the variator and undo the Central nut remove the metal ring for easier
access. Remove the nut, note the Position of the Washers and remove the front
pulley.Andremoveentire variator assembly from The shaft. Replace old, worn variator rollers.
Put variator assembly onto the shaft. Press Pulleys halves apart and let the belt slide between
them. Fit the bushing and any Spacers Put on all washers and the central nut,and tighten nut.
This may be a two-man Job. Undo the central nut, eg. With a strap wrench/ universal oil filter
wrench. You can Create a spindle with a threaded rod. Attach the spindle. Undo the nut,and
loosen the Clutch assembly using the spindle ,You can now see the tension-free
spring .Remove the Clutch from the pulley .Fit new clutch linings with new circlips.

3.1.8.Front Disk Pad Change

 Removing the Wheel. Before starting, make sure your vehicle is parked on
 A flat level surface and you have your parking brake set.
 Remove Old Brake Pads and Open Piston.
 Installing New Brake Pads.
 Close Up the Caliper.
 Reattach the Wheel. ...
 Test Brakes

3.1.9. Battery Accessories Change

 Read the manual (RTFM)

 Find the battery, and then access it
 Disconnect the negative cable
 Remove the positive cable
 Remove the battery

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 Install the new battery (or the charged one if you pulled yours out to charge it)
 Hook up the cables
 Test it
3.1.10.Spark Plug Change

 Disconnect the spark plug lead. Then, clean the area around the spark plug to avoid
getting debris in the combustion chamber when you remove the plug.
 -Remove the spark plug using a s park plug socket.
 -Clean light deposits from the plug with a wire brush and spray-on plug cleaner.

3.1.11.Front Suspension Change.

 Safety First:
 Ensure the scooter is on a stable surface , and use appropriate safety gear.
 Elevate the Scooter: Lift the front of the scooter using a center stand or a suitable lift
to access the front suspension.
 Remove Front Wheel:nLoosen the axle nut, remove the front wheel, and set it aside.
 Disconnect Brake Caliper: Detach the brake caliper from the fork, ensuring not to
stress the brake line.
 Loosen Triple Clamp Bolts: Loosen the bolts on the triple clamp that secure the front
forks.
 Remove Handlebars: If necessary, remove the handlebars to ease fork removal.
 Disconnect Front Forks: Slide the front forks out of the triple clamp carefully.
 Replace Front Suspension: Swap out the old suspension with the new one, ensuring
it's the correct
 Reassemble: Reverse the disassembly steps, reattaching the forks, handlebars, front
wheel, brake caliper, and tightening all bolts to the recommended torque.
 Check and Adjust: Verify that all components are securely fastened. Adjust the
suspension settings if necessary based on the new components.

3.1.12.Silencer Replace

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 Safety Precautions: Ensure the scooter is on a stable surface, and wear appropriate
safetygear.
 Elevate the Scooter: Lift the rear of the scooter using a center stand or a suitable lift.
 Locate and Disconnect the Silencer: Identify the connection points of the existing
silencer. Typically, it's connected to the exhaust pipe and secured with bolts.
 Loosen Bolts: Use the appropriate tools to loosen and remove the bolts securing the
silencer to the exhaust pipe.
 Remove the Old Silencer: Once the bolts are removed, carefully detach the old
silencer from the pipe. It might require a bit of twisting or wiggling.
 Install the New Silencer: Align the new silencer with the exhaust pipe and secure it in
place using the bolts. Make sure it's tightened properly.
 Check Seals and Gaskets: Ensure that any seals or gaskets between the exhaust pipe
and the silencer are in good condition. Replace if necessary.
 Adjust and Align: Adjust the position of the new silencer to align it correctly with the
scooter's body. It should be parallel and secure.
 Tighten Bolts: Double-check the tightness of all bolts to prevent any leaks or
vibrations.
 Start the Scooter: Start the scooter and listen for any unusual sounds. Check for any
visible signs of exhaust leaks around the silencer.

3.1.13.Accident Bike Repair.

 Assessment: Examine the scooter thoroughly to identify all damaged Check for structural
damage, bent frames, and any other issues.
 Order Parts: Make a list of required replacement parts and order them Ensure you get genuine
or high-quality parts for a reliable repair .
 Safety First: Use appropriate safety gear. If the damage is extensive, consider seeking
professional help.
 Disassembly : Take apart the damaged components carefully. This may include removing
body panels , wheels , and other parts affected by the ccident.
 Frame Straightening : If the frame is bent, use appropriate tools to straighten it. Precision is
crucial to maintain the scooter's integrity.
 Replacement of Damaged Parts: Replace damaged components with new ones. This may
include the handlebars, mirrors, lights, and other body parts.

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 Aligning Components: Ensure all replaced components are correctly aligned and securely
attached.
 Painting: If the repair involves repainting , do so with theappropriate color matching the
original. Follow proper painting procedures for a professional finish.
 Electrical Check: Inspect the electrical system for any issues. Ensure lights, indicators, and
other electrical components are functioning correctly.
 Brake and Suspension Check: Inspect the brakes and suspension system. Replace or repair
any damaged parts to ensure optimal safety.
 Test Ride: After reassembly, take the scooter for a test ride in a controlled environment to
ensure everything is functioning as it should.
 Fine-Tuning: Make any necessary adjustments based on the test ride. This may include
tweaking suspension settings or adjusting brakes.
 final Inspection: Double-check all repairs and ensure everything is in
 working order. Look for any signs of loose bolts or overlooked issues.

3.1.14.Engine Work.

 Safety First: Ensure the scooter is on a stable surface, and use appropriate safety gear.
Disconnect the battery to prevent electrical accidents.
 Assessment: Identify the extent of the engine damage. Look for visible damage, leaks,
or any signs of internal issues.
 Remove Engine: If the damage is significant , you may need to remove the engine for
a more thorough inspection and repair. Follow the manufacturer's service manual for
guidance.
 Inspect Components: Examine the engine components, including the cylinder,
piston,crankshaft, and other critical parts. Look for cracks , bent components , or any
signs of damage.
 Replace Damaged Parts: If any engine parts are damaged, replace them with new,
compatible components. Pay attention to seals and gaskets.
 Clean and Lubricate: Clean engine parts thoroughly and ensure proper lubrication.
Follow the manufacturer's specifications for oil type and quantity.
 Timing Adjustment: If the accident affected the timing components, such as the
camshaft or timing belt, adjust them to the correct specifications.
 Check Ignition System: Inspect the ignition system , including spark plugs and wires.

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Replace any faulty components .

 Fuel System Inspection: Check the fuel system for damage. Clean or replace the
carburetor , fuel filter, and lines as needed.
 Cooling System Check: Inspect the cooling system. Ensure the radiator is in good
condition, and the coolant is at the correct level.
 Electrical Connections: Reconnect any disconnected electrical components. Ensure all
wires are properly insulated and connected.
 Battery Re connection: Reconnect the battery and check for proper voltage. Charge or
replace the battery if necessary.
 Test Run: Start the engine and listen for unusual sounds. Monitor for leaks and check
if the engine runs smoothly.
 Performance Test: Take the scooter for a short test ride. Pay attention to engine
performance , acceleration , and overall responsiveness.
 Final Inspection: After the test run, inspect the engine again for any issues. Tighten
any loose bolts and ensure all components are secure

3.1.15.Throttle Body Cleaning .

 Gather Materials: Ensure you have a throttle body cleaner, a soft brush, a clean Cloth,
and screw driver.
 Locate the Throttle Body: Find the throttle body, usually Connected toThe air intake
system. Refer to your bike’s manual if needed.
 Remove Air Intake Hose: Use a screwdriver to loosen the clamps securing the air
intake hose to the Throttle body, then detach the hose carefully.
 Clean the Exterior: Wipe the exterior of the throttle body with a clean cloth to remove
any loose dirt or debris.
 Spray Throttle Body Cleaner: Spray throttle body cleaner into the throttle body,
targeting the throttle plate and surrounding areas.Be cautious not to over spray.
 Brush and Wipe: Gently use a soft brush to scrubaway any deposits on the throttle
plate and interior surfaces .Wipe off excess cleaner with a clean cloth.
 Reattach Air Intake Hose: Once the cleaner has evaporated, reattach the air intake
hose and tighten the clamps securely.
 Start the Engine: Start the engine and allow it to run for a few minutes. This helps to

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You can create a spindle with a threaded rod.

 Attach the spindle. Undo the nut,And loosen the clutch assembly using the
spindle ,You can now see the tension-free spring .Remove the clutch from the
pulley .Fit new clutch linings with new circlips

3.1.16.Timing Chain Repair

 Safety First: Ensure the scooter is on a stable surface with the engine turned off
disconnect the battery to prevent any electrical hazards.

 Remove Body Panels: Take off the necessary body panels to access the engine
components . Refer to the Scooter’s manual for panel removal instructions.

 Drain Fluids: Drain the engine oil and coolant to avoid spills during the repair.

 Access Timing Chain Cover: Locate the timing chain cover, which protects the timing
chain And other related components. Remove it carefully.

 Align Timing Marks: Rotate the engine to align timing marks on the crankshaft and
camshaft.

 Remove Timing Chain: Loosen and remove any tensioners, guides, or bolts securing
theTiming chain. Take note of their positions for reassembly.

 Inspect Components: Examine the timing chain , tensioners , guides, and sprockets for
wear or Damage .Replace any parts that show signs of wear.

 Install New Timing Chain: Carefully install the new timing chain, ensuring it aligns
with the timing Marks. The service manual for proper installation procedures.

 Reassemble Components: Reinstall tensioners, guides, and the timing chain cover.
Make sure all components are securely in place.

 Refill Fluids: Refill the engine with the appropriate oil and coolant.

 Check Timing: Double -check the timing by rotating the engine to ensure the marks
still Align. This is a critical step to prevent engine damage

3.2.Skills attained.

 Hands-on experience in a specific industry or field.

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 Exposure to real-world projects and problems.

 Networking opportunities with industry professionals.
 Development of practical skills such as project management, teamwork, and
communication.
 Opportunity to apply classroom learning to real-world situations.
 Chance to gain insight into potential career paths and make informed decisions about
future education or employment..

CHAPTER 4
RECOMMENDATION & CONCLUSION

4.1.Recommendation:

The nexa indus motors is a one of its kind in the automobile industry. It is best for the middle
class earning people. Because of its compact shape and small size, it is perfect for daily use.
But to long last the good performance of this care some measures should be taken.

• Always try to maintain a fixed speed limit.

• Do general servicing after running fixed km or after certain time.

• Change air filter, oil filter and lubricating oil after certain period.

• Use high grade fuel if possible.

4.2.Conclusion:

My internship experience at aaryan motors Kanhangad has been invaluable in providing

hands-on insights into the automotive industry. From daily operations to customer
interactions, I’ve gained practical knowledge that complements my academic learning. I

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appropriate the support and mentorship received from the team, contributing to my
professional growth. This experience has reinforced my passion for the automotive sector and
equipped me with skills essential for my future endeavors. I am grateful for the opportunities
and look forward to applying these learnings in my career ahead.

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