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.

Table 2.1 Corrective Action

Issue	Solution
Our group had to share the engine with another group.	Several members from each group would participate every time work was done on the engine in order to assure that both groups had knowledge of the entire dissection process.
Some tools were unavailable in the lab room.	This issue occurred several times. When we needed larger allan wrenches, we were able to utilizes supplies from the SAE club to solve this problem. The second time was when a tool was needed to remove clips holding gears in place. In the absence of the proper tool we improvised with screw drivers and a can opener.
Some group members had late night classes several times per week.	In order to accommodate conflicting schedules, we simply scheduled work times so only half of our group worked at a time in order to fairly distribute work.
Off Campus Group Member	One member of our group lived off campus and had to coordinate meeting times with available transportation. When this member was unavailable, he tackled parts of the project that could be done by one person

Product Archaeology: Product Dissection

Ease of Disassembly:

Diffictulty Scale

1-10

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	Airbox with housing cover removed
2	Air Box	Separate carburetors from an air box	2	Hands	NA	Carburator separated from airbox
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	Removing plastic caps from Carburetor
5	Carburetors	Remove fuel intake line	3	Pliers	Yes, the lines are simply taken apart and replaced	Disassembled fuel intake lines
6	Carburetors	Detach metal casing opposite plastic caps	3	Philips head screwdriver	Yes, the casings are easily removed and replaced	Metal casings behind plastic caps are being removed
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	[[ individual carburetors being disassembled
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	Cam shaft chain tensioner
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	Cam shaft chain being removed
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	Spark plugs being removed from the engine
18	Cylinder Head	Remove radiator hose (previously cracked), remove cap and valve	3	Philips head screwdriver	Yes, its a simple part to replace easy	Radiator hose being removed
19	Cylinder Head	Remove left crankcase cover	3	Philips head screwdriver	Yes, it is needed to prevent wear on the alternator, easy remove	Removing left crank case
20	Cylinder Head	Remove oil pump	4	10 mm wrench	No, it is difficult to replace, requires specific knowledge to remove	Removal of oil pump
21	Cylinder Head	Remove starter motor	5	Hands	Can be removed, but not meant to be disassembled, difficult to reconstruct	Starter motor resting on the engine
22	Clutch	Remove clutch outer guide	7	Pliers	No, because removal could seriously damage the function of the engine	Clutch outer guide
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	Clutch plates being removed
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	Right crank case has been detached
27	Top Engine Block	Remove gears from casing	2	Hands	No, gears should never be removed if engine is to remain functional	Gears in their respective positions in the casing
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	Crank shaft being taken out
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	Disassembled gears
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	Shifter cam
36	Bottom Engine Block	Push out shift drum bearing, push out shift drum	4	Hands	No, damage to this could severely damage function	Disassembled shift drum system
37	Bottom Engine Block	Remove gear shift spindle assembly	5	Hands	No, it is a very intricate piece which shoudl not be disassembled	Gear and spindle assembly
38	Bottom Engine Block	Remove exhaust manifold	2	10 mm wrench	Yes, it is external of the engine and can easily be modified	Exhaust manifold removed
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

Funtional Diagram/Outline of Engine Functions