Gate 2: Dissection
Project Management: Preliminary Project Review
Cause for corrective action
Our dissection of the engine was a trying task and took all group members a significant amount of time to finish. Unfortunately, our outline did not work ideally, and we were met with a few challenges that prevented us from going about the dissection as we had originally planned. Although this shows a flaw in our first outline, it also highlights how our group was able work through these problems together, without letting them slow our dissection process. With this, we were still able to finish our work in an efficient and timely manor, while simultaneously learning the inner workings of a typical motorcycle engine. The following table shows the issues we met during the process, and how we decided to handle them in a way that would best benefit our project, and our group as a whole.
|Our group had to share the engine with another group.||
|Some tools were unavailable in the lab room.||
|Some group members had late night classes several times per week.||
|Off Campus Group Member||
Product Archaeology: Product Dissection
Ease of Disassembly:
1-Part can simply be lifted out.
2-A small ammount force is necessary for one person to remove part.
3-A tool and a small amount of force is necessary for one person to remove part.
4-Multiple tools and a small amount of force is necessary for one person to remove part.
5-Tools and moderate force is necessary for one or more people to remove part.
6-Tools and moderate force is necessary for more than one person to remove part.
7-Tools and a significant force is necessary for more than one person to remove the part.
8-Advanced tools and a significant force is necessary for more than one person to remove the part.
9-Advanced tools, excessive force and multiple group members are necessary.
10-Multiple advanced tools, excessive force and multiple group members are necessary.
Dissection Process and Documentation
|Step||Component||Description||Difficulty||Tools||Meant to be disassembled||Picture|
|1||Air Box||Remove air cleaning housing cover, remove air filter||1||Philips head Screwdriver||Yes, the air filter needs to be replaced over time|
|2||Air Box||Separate carburetors from an air box||2||Hands||NA|
|3||Carburetors||Remove seal between air box and carburetors||1||Hands||No, carburetors are not meant to be fixed, only replaced|
|4||Carburetors||Remove plastic caps on carburetors, pop out circular plastic caps on carburetors||3||Philips head screwdriver||Yes, the caps are easy to reach and replace|
|5||Carburetors||Remove fuel intake line||3||Pliers||Yes, the lines are simply taken apart and replaced|
|6||Carburetors||Detach metal casing opposite plastic caps||3||Philips head screwdriver||Yes, the casings are easily removed and replaced|
|7||Carburetors||Remove throttle cable||4||Hands||Yes, it is an integral component of the engine that is easily interchanged|
|8||Carburetors||Undo 2 nuts on each side of the carburetor, remove carburetor connecting bolt||2||10 mm wrench||NA|
|9||Carburetors||Release springs and separate each carburetor||3||Philips head screwdriver||Yes, because if one carburetor is broken, since they are so easily removed, you only need to replace that one, not all 4||[[|
|10||Cam Shaft/Chain||Remove cam chain tensioner, two bolts||4||8 mm wrench||Yes, it is needed to be removed to access the chain and other components|
|11||Cam Shaft/Chain||Remove bolts on cam sprockets, removal of cam sprockets||3||8 mm wrench||Yes, necessary to be removed to access other components|
|12||Cam Shaft/Chain||Slip out cam chain tensionor slider||1||Hands||NA|
|13||Cam Shaft/Chain||Removed cam shaft holder bolts on intake cam, lifted up intake cam to free cam, chain from gear||3||8 mm wrench||Yes, the chain is needed to get the engine to turn over, so disassembly is necessary|
|14||Cam Shaft/Chain||Pulled out cam chain||1||Hands||NA|
|15||Cam Shaft/Chain||Remove 8 bolts on exhaust cam cover using socket driver, remove exhaust cam||3||10 mm wrench||Yes, needed to be removed to access the pistons|
|16||Cam Shaft/Chain||Remove 10 head bolts, remove 2 auxiliary bolts holding head to block||3||8 mm allen wrench, 10 mm wrench||Yes, needed to be removed to access the pistons|
|17||Cylinder Head||Remove spark plugs||7||Pliers||Yes, they are simple to remove and necessary for the engine to function correctly|
|18||Cylinder Head||Remove radiator hose (previously cracked), remove cap and valve||3||Philips head screwdriver||Yes, its a simple part to replace easy|
|19||Cylinder Head||Remove left crankcase cover||3||Philips head screwdriver||Yes, it is needed to prevent wear on the alternator, easy remove|
|20||Cylinder Head||Remove oil pump||4||10 mm wrench||No, it is difficult to replace, requires specific knowledge to remove|
|21||Cylinder Head||Remove starter motor||5||Hands||Can be removed, but not meant to be disassembled, difficult to reconstruct|
|22||Clutch||Remove clutch outer guide||7||Pliers||No, because removal could seriously damage the function of the engine|
|23||Clutch||Spring removal||2||Hands||No, the clutch is not meat to be taken apart|
|24||Clutch||Clutch plate removal||2||Hands||No, if the clutch were damaged, this would severely harm the working of the engine|
|25||Top Engine Block||Remove oil pump sprocket||3||8 mm wrench||No, this could seriously damage the engine|
|26||Top Engine Block||Separate right crankcase||3||Philips head screwdriver||Yes, it is needed to protect or get to other parts, so replacement would be necessary|
|27||Top Engine Block||Remove gears from casing||2||Hands||No, gears should never be removed if engine is to remain functional|
|28||Top Engine Block||Remove connecting rod bearing caps||4||Hands||NA|
|29||Top Engine Block||Remove connecting rod caps||3||8 mm wrench||NA|
|30||Top Engine Block||Removed crank shaft||8||Hands||No, it is an important part not meant to be taken apart|
|31||Top Engine Block||Remove pistons||6||Hands||No, the pistons are not meant to be disassemble, and replacement would be very difficult|
|32||Top Engine Block||Disassemble gears||10||Pliers, hands||No, taking apart the gears is very tedious, and if harmed, the engine would not function|
|33||Bottom Engine Block||Remove fork shaft, pull out shift forks||6||10 mm socket wrench||Not meant to be removed|
|34||Bottom Engine Block||Remove shift drum bearing set plate||5||10 mm socket wrench||Not meant to be removed|
|35||Bottom Engine Block||Remove shifter cam||5||6 mm socket wrench||Not meant to be removed|
|36||Bottom Engine Block||Push out shift drum bearing, push out shift drum||4||Hands||No, damage to this could severely damage function|
|37||Bottom Engine Block||Remove gear shift spindle assembly||5||Hands||No, it is a very intricate piece which shoudl not be disassembled|
|38||Bottom Engine Block||Remove exhaust manifold||2||10 mm wrench||Yes, it is external of the engine and can easily be modified|
|39||Bottom Engine Block||Remove oil pan||5||Philips head screwdriver||Yes, it is needed to be removed to access the oil filter|
|40||Bottom Engine Block||Remove oil filter||1||Hands||Yes, it is needed to be replaced over time|
Connection of Subsystems
Any product is a collection of different subsystems, with each subsystem containing its own set of subsystems all working together for a common goal. When considering the engine of the CBR 600, the primary function is conversion of chemical energy in gasoline into usable mechanical energy. The six major subsystems contributing to the whole are System Control, Intake, Energy Conversion, Transmission, Exhaust, and Lubrication and Cooling. Their relationships are outlined in