User:MAE277 36 09

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Work Proposal

The initial view of the mini-dirt bike has shown that a wide array of tools will be needed to disassemble the motor and transmission systems. The mini dirt bike has been split between two groups. Our group chose the motor and transmission systems.


  • a metric socket set will be needed, starting from a 6mm and going up to a 21 mm.
  • a 3/8 ratchet and various sizes of extensions will be needed, starting with a #1 and going up to a #4 just in case some prying becomes necessary.
  • a box end wrench set will also be needed in the same sizes of the socket set.

Engine and transmission systems

  • a piston-spring compressor
  • a leather-skin mallet and a bearing press to remove and reinstall the pressed-in bearing.


  • a drain pan for the oil inside the motor
  • a chain breaker, in order to remove the engine and transmission from the chassis of the dirt bike.

The complete dis-assembly of the dirt bike should take between 2 to 3 hours, in a non-crowded area with full tool availability.

Management Proposal

Personal Assessment

Member Strengths Weaknesses
Dan Cocciardi •Worked as a NYS Project Manager for Asbestos, Lead, and Mold removal
•Knowledge of various power tools and their proper employment: Including but not limited too, drills, skill saws, jigsaw, sawzaw, nail guns, etc.
•Engineering club President (DCC), participating in robotics and catapult construction competitions
•Knowledge of Autodesk Inventor
•very basic car repair knowledge regarding disk and drum break replacement, oil change, spark plugs, tension pulley maintenance
•Tendency to "over think" or "over complicate" a situation
•Difficulty relinquishing control
Eric Gande •Training in solid modeling
•Has done a reverse engineering project before
•Never did extensive work with an engine
Nnamaka Nwufoh •5 years in the U.S. Navy as an aircraft power plants technician
•Her specialty was in the Sikorsky's H-60 helicopters
•As a power plants technician she maintained and performed troubleshooting of the aircraft engines, Auxiliary Power Units, Gear boxes, Drive shafts and fuel and rotary systems
•Her technical expertise made her well-versed in tool and equipment mastery, and the assembly and dis-assembly of components and parts
•Technical writing
John Flight •Years of experience in the automotive industry
•Working experience in a machine shop
•Knowledge on solid modeling (Solidworks)
•Prefers to work alone
•Motivation only in the face of deadlines
Devershi Gupta •Doesn’t show up to class or group meetings •Doesn’t show up to class
Team Strengths and Weaknesses

Time Management and Team Positions

Gantt Sheet Team Members Meeting Schedule
Gantt Sheet
Team Members

Initial Product Assessment

* The engine and transmission is the main focus of dissection for Group 36. Questions relating to the product as a whole will be answered about the entire dirt bike, but questions about the the characteristic and functionality of the components will be answered in regards to the engine and transmission.

1) The product is a dirt bike. The intended use for the product is for off road transport. This model is intended for beginners to learn the basics of riding a dirt bike before they progress to a more powerful bike. The specific system of the product is the engine and transmission, which provide the power for the dirt bike.

a. This product is intended primarily for personal use. The fact that it is smaller and has a less powerful engine makes it better for casual and beginner riders as apposed to a professional rider. Professional riders would most likely use dirt bikes with 150cc engines as apposed to the smaller engine (around 90cc) of this dirt bike.
b. The function of this product is to transport a rider from one place to another with out the use of paved roads. Other than recreation, off road motorcycles are used in a variety of races such as motocross, rallies, and track racing. However, this specific product would not typically be found in races because it is a beginner model and does not have sufficient power to be competitive in these events.

2) This product functions similarly to most other motorcycles. It utilizes a kick start combustion engine, which is typical of off road motorcycles (reduces weight compared to electric start). The motor supplies power to the rear wheel via a chain. The bike only has one gear and has a pedal on the left side which switches the bike between neutral and first gear.

a. The three types of energy used are electrical, chemical, and mechanical. The turning of the magneto creates a current to power the spark plug (electrical energy). The gasoline energy stored in chemical form and is released during the combustion process. The engine uses mechanical energy to power the drive chain and rotate the rear wheel.
b. The energy put into the system is chemical in the form of gasoline. The gasoline is combusted in the engine, which is then converted to mechanical energy when it pushes the piston back. The energy stays mechanical as it turns the chain and in turn rotates the rear wheel. Electrical energy is used by the spinning of the magneto around the ignition coil to power the spark plug. The kick start utilizes mechanical energy to start the rotation of the magneto to create the electrical energy, but the energy created by the engine once it is running is used to power the magneto.

3) Initial trials of the dirt bike showed that it would start and run properly. The break and suspension systems also appeared to be working correctly.

a. All preliminary testing showed that it was operating at an expected level. The dirt bike was able to start, support the weight of the rider, and able to move (and accelerate) with the rider.
b. The only minor issue is that there is an under-inflated rear tire. Any other issues would be how efficiently the engine is running. This is not easy to determine because the history of the dirt bike is not known so we can not compare how well it is running now to when it was first produced. The only visual damage to the bike is some grinding on the engine casing and some rusted components including bolts and the exhaust.

4) The engine and transmission are the most complex parts of the bike. The internal combustion engine is also a relatively complex mechanism compared to many other tools and devices. However, this particular engine is much less complex than larger combustion engines found in cars.

a. This particular dirt bike has a four stroke single cylinder engine. The transmission only has neutral and first gear. This makes the entire system drastically simpler than even the smallest car engines. The number of components in these systems is probably around 100 parts. These parts include the piston and cylinder (the chamber they are housed in), spark plug, air intake and filter, exhaust, gas tank, chain and gears.
b. The most complex components of the bike are the engine and the transmission. They contain the most parts that move and act to convert chemical energy to rotational energy in the back wheel. Compared to other engines and transmissions however they are relatively simple. There are also only three gears plus neutral. This are shifted between using a centrifugal clutch. This eases the complexity of use, but the clutch itself is no more or less complex than a manual clutch. There are many moving parts to the entire engine-transmission assembly, but they contain much fewer parts than a full sized car engine and transmission. Thee one cylinder requires a decent number of moving components, but this does not compare to the timing required for a four or six cylinder engine. There are also less gears to shift between and less complex gear ratios (also there is no need for a reverse because it is a motorcycle).

5) The materials used in the engine are steel, aluminum, and rubber. Some parts will have some kind of coatings to prevent corrosion. Galvanized and stainless steel are two examples of this as well as copper coatings. The visible components can be tested with a magnet to see whether they are steel or aluminum. Most grades of steel are magnetic, while aluminum is not.

a. The clearly visible materials are aluminum and rubber.The outer parts of the engine and transmission (the housings) are made of aluminum. There also wiring coming out of the transmission housing that has a rubber sheathing. The most common type of wiring is copper and there is no reason to suspect it to be made of anything else. The spark plug has some steel on it (the bolt section), but also appears to have a plastic insulated section.
b. The internal components are probably made of aluminum, steel, copper, and rubber as well. There is going to be wiring inside the housing so copper and rubber are necessary. Steel is required for the parts of the engine that are going to be under the most stress. Aluminum is still a useful metal because it is light weight and would still most likely be used inside the engine and transmission.

6) I would be happy with this product because I never rode a motorcycle before and a dirt bike with a small engine would be a good place to start. This particular dirt bike is also easy to use because it only has one gear and would make getting use to a motorcycle easier.

a. The product felt comfortable enough to use. The seat and suspension made it comfortable to sit on and ride on paved surfaces. The intended use of the product is inherently uncomfortable however and if the bike were to be used in an off road setting the bike would probably become a less physically comfortable vehicle. The controls are also intuitive and straight forward. The simplicity of the controls would make the bike comfortable during its intended use.
b. The product is very simple to use. It starts in neutral with a kick start engine and is ready to be ridden once you put it in gear. To accelerate you rotate the throttle on the right handle bar away from you. The rear wheel break is by your right foot and the front wheel break is by your right hand. These things are easily seen upon initial inspection of the dirt bike.
c. As with all combustion engines maintenance is required. As stated in earlier this dirk bike is markedly simpler than other internal combustion engines; however this is still a somewhat complex machine. Servicing this product would probably be difficult for your average person. Someone with a decent amount of knowledge on the workings of an engine would most likely find this dirt bike easy to work on.

7) An alternative vehicle to the dirt bike would be an ATV. ATV’s give better stability and more power. ATV’s also have bigger engines, the smallest one being around 110cc, while dirt bike engines can be as low as 70cc. Comparable dirt bikes with engines around 90cc can offer different features such as auto start, a greater suspension compression, and alternate wheel sizes.

a. Group 36's dirt bike is about $700.00. Other dirt bikes of comparable size are also around this price. Other companies have their dirt bikes listed at $669.95 and $559.00. ATV’s with 110cc engines are also around $700.00 as well. These can be seen by visiting any online shops that sell off road vehicles.
b. Advantages of other bikes with greater compressibility in the suspension will be to more comfortably get over rough terrain. Larger wheels will give greater ground clearance. Larger engines will give other bike more power allowing it to move and accelerate faster. ATV’s will allow someone to have more stability over rough terrain. The wider base of the ATV allows for more balance for the rider, especially in situations of loss of traction. However, the wider size will reduce maneuverability compared to the dirt bike.
c. Most other dirt bikes are an improvement over this product in terms of performance. Larger engine sizes and variable gears will improve how well the dirt bike runs. However, the benefit of our product is that it is easy to use. Other products are more difficult to start and the increase in power would make them harder to handle than this beginner dirt bike.