Gate 4: Product Explanation

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Product Archaeology: Product Explanation

\'\'\'Product Reassembly\'\'\'

\'\'Difficulty Scale:\'\'

Level Description
1 Easy assembly with minimal tools and no difficulties
2 Moderately easy; Required some basic tools; manual referencing used
3 Parts had to be adjusted accordingly; Some special tools that were not in the shop had to be used; Time consuming
4 Parts with many sub-systems were time consuming to reassemble; Certain parts that were reassembled already had to be removed to accommodate for other parts that were not fitting back correctly
5 More than one group member was required to help reassemble one of the components; Certain parts would not be attached as easily as was disassembled prolonging the reassembly


\'\'\'How was the product originally assembled?\'\'\'

Overall, as a group, we were able to accomplish the task of first disassembling the engine and now reassembling. Although we found a bag of extra screws in the intake compartment, left by the last group, we were able to use some of the parts as replacements to certain bolts we could not find. After seeing the final project, we as a group can say that this engine could possibly be in full running condition IF AND ONLY IF ALL BOLTS AND WASHERS WERE IN PLACE and the timing chain was correct.

\'\'\'Is the assembly the same as the disassembly?\'\'\'

We would have to say yes, the assembly process should be the same as the disassembly process, but as we were doing the reassembly process, we did not use any of the pictures we took as reference. We just assembled what we thought should go first evidently leading us into some problems and obstacles. So in the long run, it was better off referring to our disassembly process.


\'\'Reassembly Steps\'\'

\'\'\'1) Transmission\'\'\'

-The Transmission Gears were attached on both the main and counter shafts

-It was then places into the Transmission Casing

-\'\'Difficulty\'\': Level 1:The gears were very simple to reassemble. Tools were not necessary during this process; however, manipulating the gears and spacing was required to get them back in the proper position.

-\'\'Tools\'\': 8, 10, and 12 mm socket wrenches

Transmission Assembly.jpg

\'\'\'Figure 1:\'\'\' Pictured is the Transmission reassembled

\'\'\'2) Clutch\'\'\'

-The clutch and friction plates were placed in the Clutch Basket

-The four Clutch Springs and Pressure Plate were mounted on the basket and the entire basket was attached to the side of the transmission

-The cover was slid fastened around the clutch

-\'\'Difficulty:\'\' Level 1: A couple of bolts and springs attached the clutch basket in place, so reattaching this subsystem back in place was not an issue. Although, one out of four of the screws that held the part in was missing. Missing a bolt can evidently affect the overall stability of the engine. Overall, the reassembly of this part was fairly simple.

-\'\'Tools:\'\' 10 mm socket wrench

Clutch Assembly.jpg

\'\'\'Figure 2:\'\'\' Pictured is the Clutch assembled before the cover was attached over it

\'\'\'3) Crankshaft\'\'\'

-All that was needed to reassemble the crankshaft was to place it in the casing next to the transmission

-\'\'Difficulty:\'\' Level 1

-\'\'Tools:\'\' None

Crankshaft Assembly.jpg

\'\'\'Figure 3:\'\'\' Pictured is the Crankshaft assembled in the casing next to the Transmission

\'\'\'4) Piston Assembly\'\'\'

-The Pistons were placed in their respective cylinders

-The connecting rods were then attached to each of the pistons and the respective place on the crankshaft from behind

-\'\'Difficulty:\'\' Level 3: When reassembling the pistons, we had realized that the piston had to placed on a certain way, or else we were not going to be able to attach the screws that held the piston to the crankshaft. We ran into a problem where we noticed that one of the pistons o-ring that secured the piston tightly to the crankshaft was missing. We decided to remove the pistons that were already attached to see if they were on them. As we eventually found out, there were two extra o-rings on the other pistons. Overall, if we didn’t run into this problem attaching the pistons to the engine would not have been as bad. The overall process of attaching all four pistons, took about half an hour.

-\'\'Tools:\'\' 8 and 10 mm Socket Wrench

Piston Assembly.jpg

\'\'\'Figure 4:\'\'\' Pictured are the Pistons being placed into their respective cylinders

\'\'\'5) Crankcase\'\'\'

-The upper half of the Crankcase was placed on the lower half and the respective screws were fastened in their respective places.

-\'\'Difficulty:\'\' Level 1: Overall, this system was fairly easy to attach. There were only a few bolts attaching this part to the overall engine. We did have trouble finding all the bolts that did attach this part to the engine. The mission bolts must have been from the previous groups from last year. We made sure that all the corresponding bolts were in separate Ziploc bags.

-\'\'Tools:\'\' Rubber Mallet - 10 mm Socket

Crankcase Assembly2.jpg

\'\'\'Figure 5:\'\'\' Pictured is the Crankcase being attached to the engine

\'\'\'6) Starter\'\'\'

-The Starter Component was placed in its covering and the two end caps were fastened together

-Placed in its respective spot on the engine and fastened to the Block

-\'\'Difficulty:\'\' Level 3: The starter gave us some minor problems when reattaching it back to the overall engine. One of the bolts sticking out from the side of the starter was off centered, interfering with the placement of the system. Evidently, we had to open the started to fix the problem, which took a bit more time, but was solve quickly. Another issue with the starter was that we as a group could not decide how the starter was attached to the engine. There were two ways to attach it, but after discussion and debate, we had come to a conclusion. The right way we mention was missing a spacer, which filled the gap between the engine and starter.

-\'\'Tools:\'\' 8 mm socket Wrench

Starter Assembly.jpg

\'\'\'Figure 6:\'\'\' Pictured is the Starter reassembled, placed on the engine

\'\'\'7) Alternator\'\'\'

-The Alternator and its cover were fastened onto the engine

-\'\'Difficulty:\'\' Level 1: The alternator was very simple to reattach. Only a few bolts held it in place so reassembling it back onto the engine was not an issue.

-\'\'Tools:\'\' 8 mm Socket Wrench

Alternator Assembly.jpg

\'\'\'Figure 7:\'\'\' Pictured is the Alternator assembled onto the engine block

\'\'\'8) Camshaft Assembly\'\'\'

-The two camshafts were placed in the head on their respective sides

-The covers were then fastened on top, over each camshaft

-\'\'Difficulty:\'\' Level 5: This was this one of the hardest subsystems to reassemble. Since the chin was in high tension it was hard to attach to the two camshafts. Also the camshafts had to sit in a specific position, so that also factored into a problem we ran into. It took two people get the cam chain back in to the camshaft. This engine was worked on by two groups this semester so during the reassembly, a few people were working on the head while a couple of people were working on the block itself. Putting the two parts together, we found out that we had to bolt down the head to the block so certain parts had to be undone. This part was an insufficient use of time.

-\'\'Tools:\'\' 10 mm Socket Wrench

Camshaft Assembly.jpg

\'\'\'Figure 8:\'\'\' Pictured are the Camshafts being assembled into the Engine Head

\'\'\'9) Timing Chain\'\'\'

-The Timing Chain\'s tensioner and guides were fastened to the engine

-The Chain was then fitted around the gears of the camshafts and the crankshaft so the teeth of each of the gears fit into the chain

-Finally the tensioner was tightened so the chain fit securely

-\'\'Difficulty:\'\' Level 4 The Timing Chain, Camshafts, and Crankshaft had to be situated many times so that they would fit perfectly into each other.

-\'\'Tools:\'\' 10 and 14 mm Socket Wrench

IMG 0028.jpg

\'\'\'Figure 9:\'\'\' Pictured is the timing chain being reassembled with the guides, sprocket, and tensioner already assembled

\'\'\'10) Valve Cover\'\'\'

-The valve cover was placed on the Engine Head over the camshafts and their covers

-Then is was secured into place by its respective bolts

-\'\'Difficulty:\'\' Level 1

-\'\'Tools:\'\' 10 mm Socket Wrench

ValveCover Assembly.jpg

\'\'\'Figure 10:\'\'\' Pictured is the Valve Cover being placed onto the engine head

\'\'\'11) Carburetor\'\'\'

-The Components of the Carburetor were assembled together into each of the 4 carburetors.

-They were then connected together by a rod

-\'\'Difficulty:\'\' Level 4: The carburetor is the most complex part of the engine due to the small components that consist of this subsystem. Group 13 did more detail research and break of the carburetor. Reassembling this component took a while, but using the half of the carburetor that was in tacked as a reference, minimized the time and simplified the process.

-\'\'Tools:\'\' 10 mm Socket Wrench - Philips Head Screwdriver - Rubber Mallet

Carburetor Assembly.jpg

\'\'\'Figure 11:\'\'\' Pictured are the Carburetors being assembled to each other

\'\'\'12) Air box\'\'\'

-The filter was placed inside the air box and then the top and bottom halves were secured together

-The carburetors were attached to the bottom of the air box

-Finally the Air Box was fastened to the the top of the completed engine

-\'\'Difficulty:\'\' Level 1

-\'\'Tools:\'\' Philips Head Screwdriver

AirBox Assembly.jpg

\'\'\'Figure 12:\'\'\' Pictured is the Air box and carburetors assembled to each other


\'\'\'Design Revisions\'\'\'

\'\'Revision #1\'\'

The first revision would be to the air intake system. I would change the intake from the basic intake into a cold air intake system. This is a very inexpensive change that would increase the performance of the engine tremendously. A cold air intake is a system used to bring down the temperature of the air going into a car for the purpose of increasing the power of the internal-combustion engine. It also increases the appeal of a motorcycle by changing the appearance of the motorcycle’s engine bay and creating an attractive intake noise.


\'\'Revision #2\'\'

The second revision that we would suggest would be the addition of a CVT (Continuously Variable Transmission) system instead of the original transmission system. This type of transmission is new technology for many people and has been seen on snowmobiles and now a few makes of Nissan. The CVT transmission has the ability to provide an unlimited range of gear ratios in the transmission. A CVT uses a pulley and belt system to provide an unlimited range of gear ratios. It is different from the Honda transmission which has a set number of gear ratios. A CVT uses parts such as a high density rubber/metal belt, a driving pulley actuated by a hydraulic cylinder, a mechanical torque-sensing driving pulley, sensors and microprocessors to perform its function. In order to add this transmission the old subsystem transmission would have to be completely removed and replaced with the CVT. The CVT transmission comes in a set package but does include the parts listed above. For the following reasons the CVT motor is highly recommended:

• Improved fuel economy

• Less emissions

• Quicker acceleration


\'\'Revision #3\'\'

The last revision for the systematical part of the engine that I would suggest is Tool-less Air Cleaner Cover. The normal air filter is located on top of the engine block and requires tools to remove and change. Thus, making it very hard to change the air filter without several tools. However, if we could add a tool-less air cleaner cover it would provide easy access to air filter changes. Although this seems very basic many people end up spending money for a mechanic to change their air filter because they do not know where it is located or how to remove it. Overall this would make it better for the user at a cost of close to nothing for the manufacturer.