Yamaha Project Machining

Engineering Project Report

On

Yamaha Manufacturing PlantFaridabad

&IC Engines

By student of

Delhi College Of Engineering

Student: Tarun PrakashRoll No.: 2K8/ME/314Branch: Mechanical Engineering

Date: 01-06-11 to 31-07-11

ACKNOWLEDGEMENT

I have learned about different operations involved in Machining of some Internal Combustion Engine Parts, Copper Plating of gears and Painting of aluminium and plastic parts used in the Yamaha motorcycles.

The machines used by Yamaha to get the best product output are really worth mentioning. There is well qualified, intelligent & co operative staff who has helped me during my training and made my training so easy.

Under the guidance of Mr. AK Mahajan, I have successfully completed my vocational training for eight weeks i.e. from 1 June 2011 to 31 July 2011. I also pay my sincere thanks to Mr. Gopal Prasad.

I would like to thank, with great regards to all Yamaha staff and Yamaha which gave me chance to improve my industrial knowledge.

CONTENTS

Yamaha Overview Yamaha Profile Yamaha Craftsmanship Layout of Yamaha Motors Paint Shop ABS Paint Shop Procedure and Operations MS/AL Paint Shop Procedure and Operations Layout of Machine Shop Connecting Rod machining Procedure and

Operations Body Cylinder machining Procedure and

Operations Camshaft Machining Procedure and

Operations Copper Plating Procedure and Operations Alodine Treatment Procedure and Operations Yamaha Bikes

CRUXALBAG5GLADIATOR SSGRAFFITIR15R1FZSF15FAZERMT01

IC Engine and its Parts Engine Glossary

YAMAHA OVERVIEW

Founded - July 1, 1955

Capital - 48,302 million yen (as of March 31, 2008)

President - Takashi Kajikawa

Employees(Consolidated)-46,850(December31,2007) Parent: 9,019 (December 31, 2007)

Sales(Consolidated)1,756,707millionyen(fromJanuary1,2007toDecember31,2007)Parent:799,209millionyen(from January 1, 2007 to December 31, 2007) Sales Profile

Sales (%) by product category (consolidated)

Sales (%) by region (consolidated)

Major Products & Services

Manufacture and sales of motorcycles, scooters, electro-hybrid bicycles, boats, sail boats, Water Vehicles, pools, utility boats, fishing boats, outboard motors, diesel engines, 4-wheel ATVs, side-by-side vehicles, racing karts, golf cars, multi-purpose engines, generators, water pumps, snowmobiles, small-sized snow throwers, automotive engines, intelligent machinery, industrial-use remote control helicopters, electrical power units for wheelchairs, helmets. Biotechnological production, processing and sales of agricultural and marine products and microorganisms. Import and sales of various types of products, development of tourist businesses and management of leisure, recreational facilities and related services.

Headquarters : 2500 Shingai, Iwata-shi, Shizuoka-ken, Japan

YAMAHA PROFILE

Yamaha made its initial foray into India in 1985. Subsequently, it entered into a 50:50 joint venture with the Escorts Group in 1996. However, in August 2001, Yamaha acquired its remaining stake becoming a 100% subsidiary of Yamaha Motor Co., Ltd, Japan (YMC). In 2008, YMC entered into an agreement with Mitsui & Co., Ltd. to become a joint investor in the motorcycle manufacturing company "India Yamaha Motor Private Limited (IYM)".

IYM operates from its state-of-the-art-manufacturing units at Surajpur in Uttar Pradesh and Faridabad in Haryana and produces motorcycles both for domestic and export markets. With a strong workforce of more than 2000 employees, IYM is highly customer-driven and has a countrywide network of over 400 dealers. Presently, its product portfolio includes MT01 (1670 cc), YZF-R1 (998 cc), the all new YZF-R15 (150 cc), FZ16, FZ-S, Fazer (153cc), Gladiator Type SS & RS (125 cc), Gladiator Graffiti (125cc), G5 (106 cc), Alba (106 cc) and Crux (106 cc).

India Yamaha Motor inaugurated New Plant at Surajpur (GreaterNoida)

The new Surajpur plant has been inaugurated by Mr. T.Kazikawa C.E.O & MD Yamaha Global on 6th July 2009, which have capacity to produce 6 lakh motorcycles annually including Fazer followed by FZ-16, FZ-S, YZF-R15 and other models. The plant capacity can be augmented up to 1 million units.

This fully integrated assembly plant is built on the lines of Yamaha’s globally tried, tested and successfully implemented standards and meets the global quality benchmarks. At the core are the 5-S and TPM activities that fuel its Manufacturing Processes. The plant has 3 vehicle assembly lines and 4 engine assembly lines including one dedicated for export engines. The engine and vehicle assembly lines are synchronized and incorporate concepts of Unit Assurance i.e. Complete Product Assurance, Parts Assurance through 100% kit supply on lines and synchronization of parts storage, supply and production.

VISION:

YAMAHA as the "exclusive & trusted brand" of customers by "creating Kando" (touching their hearts) - the first time and every time with world class products & services delivered by people having "passion for customers".

YAMAHA CRAFTSMANSHIP

Higher, ultimate quality − Re-examining the essentials of product creationEver since its founding, Yamaha Motor Company has made “High-quality Product Creation” one of its mottos. That means the pursuit of not only durability, reliability and quality finish but also sensibilities that touch the human heart and ingenuity that creates new value and appeal. It is nothing less than using the most advanced technologies available at the time and refined sensibilities to create and supply products that no other maker can imitate. What’s more, the “high quality” we aim for does not stop at simply the quality of the product. It extends to an uncompromising concern for high quality in all aspects of the product creation process, from the product development stage to design, manufacturing, sales and after-sale service.

To be Your Only One brand, always a step ahead, always the standoutIt’s the Yamaha Spirit to always take the next step forward, to take on the challenges that raise the bar and give birth to new technologies that only Yamaha Motor can offer, technologies that create new value that didn’t exist before. We are using innovative thought to take on the issues of environmental friendliness, to find attractive new features and ways to improve safety. We are working to find answers one after another for a wide range of issues. By opening up new technological frontiers based on perceptive visions of the changing times, while also continuing to refine existing technologies, Yamaha will continue to strive to be Your Only One brand

Bringing people new joyBringing new fulfillment to people's livesProducts that bring exciting new joy, products that play a useful role in people's lives, products that serve in numerous industries. Yamaha products are ones that continue to evolve while serving as integral parts of people's lives all over the world. Our aim is to further refine the "Humachine Technology" that creates the unity of rider and machine. This enables us to continue to offer the customers value they won't find anywhere else in the areas of people-friendliness, environment-friendliness, Design & Performance, reliability, just-fit solutions and ease and convenience of use. We at Yamaha Motor consider this to be our mission.

LAYOUT OF YAMAHA MOTORS

GATE

G T Administrative Block Administrative Block Casting Shop DIE ALODINE CASTING TREAT- SHOP MENT Machine Shop PLANT Paint Shop

MS / AL ABS

Staff Mess

SB BF HT Copper Plating Store Power House

MS: Mild Steel SB:Shot Blasting AL: Aluminium BF: Buffing

ABS: Acrylonitrile Butadiene Styrene HT: Heat Treatment GT: Gate

PAINT SHOP

ABS : Acrylonitrile butadiene styrene (ABS) (chemical formula (C8H8· C4H6·C3H3N)n) is a common thermoplastic used to make light, rigid, molded products such as piping (for example plastic pressure pipe systems), musical instruments (most notably recorders and plastic clarinets), golf club heads (used for its good shock absorbance), automotive body parts, wheel covers, enclosures, protective head gear, buffer edging for furniture and joinery panels, airsoft BBs and toys, including Lego bricks.

AL/MS:(Aluminium/Mild Steel)Aluminium is a soft, durable, lightweight, malleable metal with appearance ranging from silvery to dull grey, depending on the surface roughness. Aluminium is nonmagnetic and nonsparking. It is also insoluble in alcohol, though it can be soluble in water in certain forms. The yield strength of pure aluminium is 7–11 MPa, while aluminium alloys have yield strengths ranging from 200 MPa to 600 MPa. Aluminium has about one-third the density and stiffness of steel. It is ductile, and easily machined, cast, and extruded. Aluminium is remarkable for its ability to resist corrosion.Eg.Transportation (automobiles, aircraft, trucks, railway cars, marine vessels, bicycles etc.) as sheet, tube, castings etc.

PAINT SHOP

ABS PAINT SHOP

MS/AL PAINT SHOP

ABS PAINT SHOP PROCEDURE

LOADING PRE TREATMENT

DRY OFF OVEN

WIPING WITH IP

WIPING WITH TAG RAG

AIR BLOW OPERATION

PAINT KITCHEN

BAKEOFF OVEN

INSPECTION

UNLOADING

OVERVIEW OF THE OPERATIONS

LOADING:The workpiece is hang on the hangers. These hangers are temporarily attached to the jigs. These jigs are keep on moving continuously by conveyors.

PRETREATMENT:After loading the work-piece, it undergoes the process of “pretreatment”.In this process chemical water (mixture of DM water and Surf Power) is use to remove grease, stains etc. from the job.The spray pressure of water is 0.5 to 0.8 kg/cm².Temperature is about 55 to 65°C.

DRY OFF OVEN: The dry off oven make the job, after the water treatment to get dry for further operations.

WIPING WITH IP: IP is Isopropyl Alcohol. It is use to remove the oil and grease from the work component after it comes from the dry off oven.

WIPING WITH TAGRAG:After IP, the component is wiped with a cloth called as “tag-rag”. This cloth is used to remove the dust particles, if any, on the component.

AIR BLOW OPERATION:After wiping the component with tag-rag, air at a very high pressure is made to strike on the component to remove water from the pockets of the component. After this operation the component enters the paint kitchen.

PAINT KITCHEN:In Paint Kitchen, two operations are performed on the component.They are following:1. Primer Coating.2. Paint (Color) Coating.

The paint and primer are sprayed through guns called as “paint guns” on the component.In Primer coating, three coats of primer is done on each and every component.

Similarly, in colour coating, again three coats of paint (colour) is done on the component.

BAKING OFF OVEN:The temperature of the Baking off oven is about 70 to 75 °C. The purpose of baking off oven is to completely dry the paint on the component. INSPECTION:After bake off oven the component is inspected thoroughly to find “a single minute defect”. The defected pieces undergo the same operations again. And the “ok “ tested pieces move in the assembly line.

UNLOADING:After the inspection, the components are removed from the hangers.

PAINT TABLE:

Paint Supplier Paint Paint Hardener ThinnerThinnerVis- Paint Temp. hu Name batch no. cosity filter m No.

POST PAINTING OPERATOINS:The paint which do not stick to the components is then carried away by the water . The paint acts like a sludge and floats on the water. This sludge is then removed. Water is treated in the RO Plant to filter it and then water is again circulated in the plant. The sludge is then burned in the furnace.

MS/AL PAINT SHOP PROCEDURE

LOADING DEGREASING(1and 2)

RAW WATER RINSE (1and2)

RO WATER RINSE(1and 2)

ALSURF TREATMENT

DI WATER RINSE (1and 2)

FINAL RINSE (DI WATER)

PAINT KITCHEN

DRY OFF OVEN

INSPECTION UNLOADING

OVERVIEW OF MS / AL PAINT SHOP

Operation 1:LOADING: The workpiece is hange on the hangers. These hangers are temporarily attached to the jigs. These jigs are keep on moving continuously by conveyors.

Operation 2 : WATER TREATMENT:DEGREASE 1 AND 2:It is done by the chemical water. This water is having a cleaner called as “surf cleaner 53”.Under it, water is sprayed at a pressure of 0.8 to 1.2 kg / cm².This process is done two times as Degrease 1 and Degrease 2.

Operation 3 : WATER RINSE 1,2,3,4,5,6:Water rinse 1 and water rinse 2 are done by raw water.Water rinse 3 is done by R.O. water.Then the component undergoes “Aluminium Treatment”. In this treatment chemical water having the chemical “Alsurf 375” is used.Then water rinse 4 is done by using R.O. water.Then water rinse 5 and water rinse 6 are done using D.I. water.Then final rinse is done using the D.I. water.In all the above processes water is sprayed at a pressure of 0.8 to 1.2 kg / cm².

Operation 4 : DRY OFF OVEN: The dry off oven make the job, after the water treatment to get dry for further operations.

Operation 5 : PAINT KITCHEN:In Paint Kitchen, two operations are performed on the component.They are following:1. Primer Coating.2. Paint(Colour) Coating.

The paint and primer are sprayed through guns called as “paint guns” on the component.In Primer coating, three coats of primer is done on each and every component.Similarly, in colour coating, again three coats of paint (colour) is done on the component.

Operation 6 : BAKING OFF OVEN:The temperature of the Baking off oven is about 70 to 75 °C. The purpose of baking off oven is to completely dry the paint on the component.

Operation 7 : INSPECTION:After bake off oven the component is inspected thoroughly to find “a single minute defect”. The defected pieces undergo the same operations again. And the “ok “ tested pieces move in the assembly line.

Operation 8 : UNLOADING:After the inspection, the components are removed from the hangers.

LAYOUT OF MACHINE SHOPGATE SIDE HD CYLINDER LINE 3 HD CYLINDER LINE 1

HD CYLINDER LINE 5 HD CYLINDER LINE 2

HD CYLINDER LINE 4 CAMSHAFT LINE 1

CRANK LINE 4 CAMSHAFT LINE 2

CRANK LINE 3

CRANK LINE 1 CRANK LINE 2

CON ROD CON ROD LINE LINE

CARRIERS TRIAL COMP. AXLE MAIN

SPROCKET GEARS LINE GEAR LINE DRIVE

AXLE MAIN GEAR LINE GEAR LINE

AXLE MAIN GEAR LINE GEAR LINE

AXLE DRIVE AND MAIN GEAR LINE GEAR LINE CRANKCASE LINE 4 BODY CYLINDER LINE 1 CRANKCASE LINE 2 BODY CYLINDER LINE 2 CRANKCASE LINE 1 BODY CYLINDER LINE 3 CRANKCASE LINE 3

CONNECTING ROD MACHINING

PIECE FROM CASTING SHOP

SURFACE GRINDING

BORING

OIL DRILLING

CHAMFERING

HEAT TREATMENT

SURFACE GRINDING

ID FOR SMALL AND BIG END

NICHING HONNING + BEND AND TWIST

GRADING

MACHINE OPERATIONS ON CON ROD

PIECE FROM CASTING SHOP:Raw piece is obtained from casting. It has already got a hole at BIG end of the con rod and hole is obtained at the SMALL end by machining

operations.

SURFACE GRINDING:Grinding practice is a large and diverse area of manufacturing and tool making. It can produce very fine finishes and very accurate dimensions; yet in mass production contexts it can also rough out large volumes of metal quite rapidly. It is done to obtain surface finish in the work-piece obtained from casting.

BORING:The big end of the connecting rod is bored to a suitable diameter which was previously solid.

OIL DRILLING:Small holes are drilled on the big and small end of the bearings. These holes are drilled for the lubrication purpose during operation.

CHAMFERING:Chamfering is done of the big and small end of the bearing.

HEAT TREATMENT:It is done to improve the mechanical properties of the connecting rod.

SURFACE GRINDING:Grinding practice is a large and diverse area of manufacturing and tool making. It can produce very fine finishes and very accurate dimensions; yet in mass production contexts it can also rough out large volumes of metal quite rapidly. It is done to obtain surface finish in the work-piece obtained from heat treatment

ID FOR SMALL END:The boring operation is done on the small end of the connecting rod to get the required diameter at the small end.

http://en.wikipedia.org/wiki/Tool_and_die_maker


http://en.wikipedia.org/wiki/Manufacturing



http://en.wikipedia.org/wiki/Manufacturing

ID FOR BIG END:The boring operation is done on the big end of the connecting rod to get the required diameter at the bigger end.

HONING:Honing is a final finishing operation conducted on a surface, typically of an inside cylinder, such as of an automotive engine block. Abrasive stones are used to remove minute amounts of material in order to tighten the tolerance on cylindricity. Honing is a surface finish operation, not a gross geometry-modifying operation. Hones can be of the multiple pedal type (pictured below) or the brush type. Either type applies a slight, uniform pressure to a light abrasive that wipes over the entire surface.

BEND AND TWIST:This is done to remove any bend present in the con rod occured during machining operations. This is done by hammering on the conrod by a hammer.

GRADING:Bearings are fitted in the big and small end of the connecting rod. The required size of the bearing is obtained by grading the con rod.GRADE 1GRADE 2GRADE 3

Thus, three grades are used to get the required size of the bearings.

BODY CYLINDER MACHINING

OD (Turning) + FACING + CHAMFER

4+ 2 DRILL (THROUGH)

CENTRING, ENDMILL, REAMING (2)

FACING, CHAMFER, DRILL2, TAPING2

WASHING

AIR LEAKAGE CHECK BORING HONING

WASHING

MACHINING OPERATIONS ON BODY CYLINDER

RAW PIECE:The piece is obtained from casting shop.

Process 1:OD (Turning) + FACING + CHAMFERIn this process, the above mentioned operations are done.Facing of both the side is done.OD is obtained by turning.Chamfering of the OD (outer diameter) is done.

Process 2:4+ 2 DRILL (THROUGH)4 drill of the same size are made through.2 drill of same size are made through.

Process 3:CENTRING, ENDMILL, REAMING (2)A process in which a rigid drill precisely locates a hole in the center of a workpiece. The purpose of center drilling is to establish a true centerline diameter.A thin, tall mill cutter with cutting edges that wind up the sides. Both the bottom and side of the end mill are used during milling operations. End mills resemble drills.The process of using a cutting tool with straight cutting edges to enlarge or smooth holes that have been previously drilled.Two reaming operations are done .

Process 4:FACING, CHAMFER ,DRILL(2), TAPING(2)In this process, facing of side part of the body cylinder is done. Thus material is removed to make the surface flat.Chamfers are made at two different positions where drill are to be made.Two different drills are made at two different positions.Taping is an operation of cutting threads at the drill.Two tappings are being done in different holes respectively.

Process 5:WASHINGIn this process the component is washed to remove the chips present, during the machining operation.

Process 6:AIR LEAKAGE CHECKAll the open holes are covered up. Then the piece is immersed in the water to check whether any bubbles are rising or not. If “yes” then the component is “rejected”. If “not”, then further operations are done on the component.

Process 7:BORINGBoring of the cylindrical part is done to the required size.

Process 8:HONINGA precision abrasion process in which a relatively small amount of material is removed from a surface by means of abrasive stones. The goal is to obtain a desired finish or extremely accurate features.

Process 9:WASHING In this operation the component is washed thoroughly to remove chips, if any present. It also washed away all the fine particles dat may be sticking to the component after honing.

CAMSHAFT MACHINING

FACING AND CENTERING

GROOVING

DRILLING

KEY WAY MILLING + TAPPING

DRILLING +DEBURRING

CAM GRINDING

JOURNAL GRINDING (ONE SIDE)

JOURNAL GRINDING (OTHER SIDE) DEBURRING+WASHING

QUALITY CONTROL CHECK MACHINING OPERATION ON CAMSHAFT

RAW PIECE:The piece is obtained from casting shop.

Process 1:FACING AND CENTERINGIn the facing operation, the surface is finished to make it a flat one. The facing is done of the two ends to the required length needed.A process in which a rigid drill precisely locates a hole in the center of a workpiece. The purpose of center drilling is to establish a true centerline diameter. It also helps to hold the component on the machine.

Process 2:GROOVINGTwo grooves are cut on the cam shaft. One on either side of the two lobes.It is a process of forming a narrow cavity of a certain depth on a cylinder, cone ,or a face or part.

Process 3:DRILLINGA central hole is made. This is also called as oil drill hole. A through hole is made in the camshaft.

Process 3:KEY WAY MILLING + TAPPINGIn this process, a key is cut on the camshaft.After this operation, tapping is done on one side of the camshaft.In the tapping operation,internal threads are cut in the workpiece.

Process 4:DRILLING +DEBURRINGSmall holes are drilled on the lobes.

Deburring is, to put it simply, a finishing method used in industrial settings and manufacturing environments. Metal is frequently machined using many processes in order to create pieces of specific shape and size. For example, metal may be welded, molded, cast, trimmed, slit or sheared. These procedures often create ragged edges or protrusions. The raised particles and shavings that appear when metal blanks are machined are referred to as burrs, and the process by which they are removed is known as deburring.

Deburring may be accomplished by one of several methods. Abrasive substances may be applied, or abrasive cloths may be used to rub the metal in order to remove thin shavings and small notches, as well as to polish the piece. In other cases, sanding may be necessary, whether this means a small amount of sanding by hand or rigorous sanding with a machine for more troublesome deformities.

Process 5:CAM GRINDINGCam lobes are grinded on the grinding machine.

Process 5:JOURNAL GRINDING In this process, part other then the lobes are grinded.

Process 6:DEBURRING+WASHINGAfter all the operations, washing is being done to remove all the chips, if any present on the component. And, afterwards, final deburring is being done.

Process 7:QUALITY CONTROL CHECKIn the quality control check, the pieces are passed through the “GO” and “NOT GO” gauges. If the piece passed through the gauge, then it is “rejected” and if not , then, it is “passed” the quality check.

COPPER PLATING PROCEDURE

PRELIMINARY DEGREASING

IMMERSION DEGREASING

ELECTROLYSIS DEGREASING

WATER RINSE

ACID DIPPING

WATER RINSE

NEUTRALISATION

COPPER PLATING WATER RINSE + OIL DIPPING

INSPECTION

COPPER PLATING DETAILS

Copper Plating is done on the gears. The gears on which the plating is done are following:4th pinion and 5th pinion.Also, 2nd wheel and 3rd wheel.

Operation 1:PRELIMINARY DEGREASINGDegreasing+ is a process that removes oils, grease, and solid dirt particles from metal surfaces. Degreasing prepares a material for finishing applications such as primers, paints, bonds, or plating.In this process, the pieces are dipped in a solution for 5 minutes.

Operation 2:IMMERSION DEGREASINGIn this operation , the gears which are hanged on the hangers are fully immersed in the alkali solution.This operation is done for five minutes.

Operation 3:ELECTROLYTIC DEGREASINGProcess for removal of grease, oil, etc from metal surfaces in preparation for electroplating. The metal is made the cathode in an electrolytic cell containing strongly basic (sometimes hot) solution that dissolves these coatings. The strong hydrogen evolution occurring on the cathode may reduce some of the coatings, and the strong bubble evolution removes the coatings mechanically, while the agitation of the solution helps the chemical dissolution of the coatings by the base. Also called: ""electrolytic cleaning,"" ""electrochemical cleaning,"" ""electrocleaning,"" and ""electrochemical degreasing."This operation is done for two minutes.

Operation 4:ACID DIPPINGIn this operation the components are dipped in the acid solution.The acid used here is HCl (hydrochloric acid).

Operation 5:WATER RINSEIn this process, the gears are dipped in water.

Operation 6: NEUTRALISATIONIn this operation, the components are dipped in the solution of KOH(potassium hydroxide).This operation is done for 30 seconds.

Operation 7: COPPER PLATINGCopper plating is the process in which a layer of copper is deposited on the item to be plated by using an electric current.With a higher current, hydrogen bubbles will form on the item to be plated, leaving surface imperfections. Often various other chemicals are added to improve plating uniformity and brightness. Without some form of additive, it is almost impossible to obtain a smooth plated surface. These additives can be anything from dish soap to proprietary compounds.This is done for 28 minutes.

Operation 8: WATER RINSE + OIL DIPPINGIn this operation ,first of all,water rinse is done.To remove the copper solution if ,sticking on the surface.Next in the row is oil dipping. This is done to avoid corrosion and any effect of the atmosphere.

Operation 9: INSPECTIONIn this process, a deep inspection of the gears are made to see ,if there is any copper plating other then at the required place.If there is no such plating, then the component is “ok” tested.Otherwise, it goes under a process to remove the plating from the non-required area.

Thus with the use of copper plating, the use of the copper bushes on gears are totally removed.

ALODINE TREATMENT

http://en.wikipedia.org/wiki/Copper

DEGREASING

WATER RINSE 1

WATER RINSE 2

WATER RINSE 3

AL SURF TREATMENT

WATER RINSE 4

WATER RINSE 5

HOT RINSE HOT AIR DRIER

ALODINE TREATMENT OVERVIEW

ALODINE CASTING MACHINING SHOP TREATMENT SHOP

After the casting shop, a coating of iodine is made on the components to avoid rust.

This is all done in alodine treatment.

Operation 1: DEGREASINGDegreasing is a process that removes oils, grease, and solid dirt particles from metal surfaces. Degreasing prepares a material for finishing applications such as primers, paints, bonds, or plating.The whole bunch of components are dipped in the degreasers for 90-120 seconds.

Cleaning agents specially made for removal of grease are called degreasers. These are solvent based or solvent containing and have also surfactants as active ingredients. The solvent have a dissolving action on grease and similar dirt. The solvent containing degreaser may be an alkaline washing agent added a solvent to promote further degreasing. Degreasing agents are also made solvent free based on surfactants.

Operation 2: WATER RINSE 1Pure Water Rinse is a soft and safe way to clean with a spot-free dry and a hard shell shine. And because it requires a minimum of water.This is done for 60 seconds.


Operation 4: WATER RINSE 3

http://en.wikipedia.org/wiki/Surfactants

http://en.wikipedia.org/wiki/Solvent

http://en.wikipedia.org/wiki/Grease

Pure Water Rinse is a soft and safe way to clean with a spot-free dry and a hard shell shine. And because it requires a minimum of water.This is done for 60 seconds.

Operation 5: AL SURF TREATMENT In this treatment, the components are treated with iodine solution. To form a coating of iodine on the surface.This process is done for 120 seconds.



Operation 8: HOT WATER RINSE This is done as the final rinse to clean perfectly the component.This is done for 60 seconds.

Operation 9: HOT AIR DRIERThis is done to dry the component completely.

YAMAHA BIKES

Yamaha Alba

ENGINE SPECIFICATIONS

Engine type Air-cooled, 4-stroke, SOHC, 2-valve

Cylinder arrangement Single cylinder

Displacement 106cc

Bore & Stroke 49.0 x 56.0mm

Maximum power 7.6PS (5.59kW) / 7,500rpm

Maximum torque 7.85N.m / 6,000rpm

Starting system Kick start / Electric start

Clutch type Multiple wet type

Gear box 4-speed constant mesh

Yamaha Crux


Engine type Air-cooled, 4-stroke, SOHC, 2-valve Cylinder arrangement Single cylinder Displacement 105.6cc Bore & Stroke 49.0 x 56.0mm Compression ratio 9.0:1 Maximum power 7.6PS (5.59kW) / 7,500rpm Maximum torque 7.85N.m / 6,000rpm Starting system Kick start Lubrication wet sump Carburetion VM17 Ignition system C.D.I. Primary / Secondary reduction ratio 3.722 / 3.143 Clutch type Wet multi-plate coil spring Transmission type 4-speed constant mesh Gear ratios 1st=3.00, 2nd＝1.688, 3rd:=1.200, 4th=0.875

Yamaha G5


Engine type Air-cooled, 4-stroke, SOHC, 2-valve Cylinder arrangement Single cylinder Displacement 106cc Bore & Stroke 49.0 x 56.0mm Compression ratio 9.0:1 Maximum power 7.6PS (5.59kW) / 7,500rpm Maximum torque 7.85N.m / 6,000rpm Starting system Kick start / Electric start Lubrication Compulsive pressure wet sump Carburetion Variable venturi type Ignition system C.D.I. Battery capacity / Type 12V, 2.5Ah Primary / Secondary reduction ratio 3.722 / 3.214 Clutch type Wet multiple-disc Transmission type Four steps of regular engagement formula advance Gear ratios 1st=3.000, 2nd＝1.688, 3rd:=1.200,

4th=0.875

Yamaha Gladiator Type SS


Engine type Air-cooled, 4-stroke, SOHC, 2-valve Cylinder arrangement Single cylinder Displacement 123.7cc Bore & Stroke 54.0 × 54.0mm Compression ratio 10.0:1 Maximum power 11PS (8.0kW) / 7,500rpm Maximum torque 10.4N.m / 6,500rpm Starting system Kick start / Electric start Primary / Secondary reduction ratio. 3.4 / 3.214 Clutch type Multiplate wet type Transmission type 5 Speed constant mesh Gear ratios 1st=3.000, 2nd＝1.777, 3rd:=1.316, 4th=1.045, 5th=0.875

Gladiator Graffiti


Engine type Single Cylinder Air Cooled, 4-stroke SOHC

Displacement 123.7cc Bore & Stroke 54×54 Maximum Power 11 bhp @ 7500 rpm Maximum torque 10.4 Nm. / 6500 rpm Compression ratio 10.0:1 Ignition CDI Clutch Multiple Wet Type Starting Kick start/Electric starter Gear Box 5-Speed Constant Mesh Fuel Tank Capacity 13 ltrs

Yamaha YZF-R15


Engine type Liquid-cooled, 4-stroke, SOHC, 4-valve

Cylinder arrangement Single cylinder Displacement 149 .8cc Bore & Stroke 57×58.7mm Compression ratio 10.4:1 Maximum power 17PS / 8,500rpm Maximum torque 15 N.m / 7,500rpm Starting system Electric Start Lubrication wet sump Engine oil capacity 1.0 liters Fuel tank capacity 12 liters Fuel supply system Electronic fuel injection Ignition system T.C.I Primary / Secondary reduction ratio 3.042 / 3.000 Clutch type Constant-mesh wet multi-plate Transmission type Return type 6-speed Gear ratios 1st=2.833, 2nd=1.875, 3rd:=1.364,

4th=1.143, 5th=0.957, 6th=0.84 Yamaha YZF-R1


Engine type Liquid-cooled, 4-stroke, forward inclined parallel 4-cylinder, 4-valve, DOHC

Displacement 998 cc Bore & Stroke 77.0 x 53.6 mm Compression ratio 12.7:1 Maximum power 132.4 kW (180 PS) @ 12,500 rpm

139.0 kW (189 PS) @ 12,500 rpm Maximum torque 112.7 Nm (11.5 kg-m) @ 10,000 rpm

118.3 Nm (12.1 kg-m) @ 10,000 rpm Starting system Electric Lubrication wet sump Carburettor/Fuel supply Fuel injection Clutch type Wet multiple-disc coil spring Ignition system T.C.I Primary / Secondary reduction ratio 3.042 / 3.000 Transmission type Constant mesh, 6-speed Final transmission Chain

Yamaha FZS


Engine type Air-cooled, 4-stroke, SOHC, 2-valve Displacement 153.0cm3 Bore & Stroke 58.0 × 57.9mm Compression ratio 9.5:1 Maximum output 14PS / 7500 rpm Maximum torque 14 N.m / 6000 rpm Starting method Electric starter Lubrication type Wet sump Carburetor type BS26 Clutch type Constant mesh wet multiplate Ignition type CDI Primary/secondary reduction ratio 3.409 / 2.857 Transmission type Return type 5-speed Fuel tank volume 12 liters Engine oil volume 1.2 liters

Yamaha FZ16


Engine type Air-cooled, 4-stroke, SOHC, 2-valve Displacement 153.0cm3 Bore & Stroke 58.0 × 57.9mm Compression ratio 9.5:1 Maximum output 14PS / 7500 rpm Maximum torque 14 N.m / 6000 rpm Starting method Electric starter Lubrication type Wet sump Carburetor type BS26 Clutch type Constant mesh wet multiplate Ignition type CDI Primary/secondary reduction ratio 3.409 / 2.857 Transmission type Return type 5-speed

Yamaha Fazer

YAMAHA BIKES Yamaha Alba



Cylinder arrangement Single cylinder

Displacement 106cc

Bore & Stroke 49.0 x 56.0mm

Maximum power 7.6PS (5.59kW) / 7,500rpm

Maximum torque 7.85N.m / 6,000rpm

Starting system Kick start / Electric start

Clutch type Multiple wet type

Gear box 4-speed constant mesh

Yamaha Crux


Engine type Air-cooled, 4-stroke, SOHC, 2-valve Cylinder arrangement Single cylinder Displacement 105.6cc Bore & Stroke 49.0 x 56.0mm Compression ratio 9.0:1 Maximum power 7.6PS (5.59kW) / 7,500rpm Maximum torque 7.85N.m / 6,000rpm Starting system Kick start Lubrication wet sump Carburetion VM17 Ignition system C.D.I. Primary / Secondary reduction ratio 3.722 / 3.143 Clutch type Wet multi-plate coil spring Transmission type 4-speed constant mesh Gear ratios 1st=3.00, 2nd＝1.688, 3rd:=1.200, 4th=0.875

Yamaha G5


Engine type Air-cooled, 4-stroke, SOHC, 2-valve Cylinder arrangement Single cylinder Displacement 106cc Bore & Stroke 49.0 x 56.0mm Compression ratio 9.0:1 Maximum power 7.6PS (5.59kW) / 7,500rpm Maximum torque 7.85N.m / 6,000rpm Starting system Kick start / Electric start Lubrication Compulsive pressure wet sump Carburetion Variable venturi type Ignition system C.D.I. Battery capacity / Type 12V, 2.5Ah Primary / Secondary reduction ratio 3.722 / 3.214 Clutch type Wet multiple-disc Transmission type Four steps of regular engagement formula advance Gear ratios 1st=3.000, 2nd＝1.688, 3rd:=1.200,

4th=0.875

Yamaha Gladiator Type SS


Engine type Air-cooled, 4-stroke, SOHC, 2-valve Cylinder arrangement Single cylinder Displacement 123.7cc Bore & Stroke 54.0 × 54.0mm Compression ratio 10.0:1 Maximum power 11PS (8.0kW) / 7,500rpm Maximum torque 10.4N.m / 6,500rpm Starting system Kick start / Electric start Primary / Secondary reduction ratio. 3.4 / 3.214 Clutch type Multiplate wet type Transmission type 5 Speed constant mesh Gear ratios 1st=3.000, 2nd＝1.777, 3rd:=1.316, 4th=1.045, 5th=0.875

Gladiator Graffiti


Engine type Single Cylinder Air Cooled, 4-stroke SOHC

Displacement 123.7cc Bore & Stroke 54×54 Maximum Power 11 bhp @ 7500 rpm Maximum torque 10.4 Nm. / 6500 rpm Compression ratio 10.0:1 Ignition CDI Clutch Multiple Wet Type Starting Kick start/Electric starter Gear Box 5-Speed Constant Mesh Fuel Tank Capacity 13 ltrs

Yamaha YZF-R15


Engine type Liquid-cooled, 4-stroke, SOHC, 4-valve

Cylinder arrangement Single cylinder Displacement 149 .8cc Bore & Stroke 57×58.7mm Compression ratio 10.4:1 Maximum power 17PS / 8,500rpm Maximum torque 15 N.m / 7,500rpm Starting system Electric Start Lubrication wet sump Engine oil capacity 1.0 liters Fuel tank capacity 12 liters Fuel supply system Electronic fuel injection Ignition system T.C.I Primary / Secondary reduction ratio 3.042 / 3.000 Clutch type Constant-mesh wet multi-plate Transmission type Return type 6-speed Gear ratios 1st=2.833, 2nd=1.875, 3rd:=1.364,

4th=1.143, 5th=0.957, 6th=0.84 Yamaha YZF-R1


Engine type Liquid-cooled, 4-stroke, forward inclined parallel 4-cylinder, 4-valve, DOHC

Displacement 998 cc Bore & Stroke 77.0 x 53.6 mm Compression ratio 12.7:1 Maximum power 132.4 kW (180 PS) @ 12,500 rpm

139.0 kW (189 PS) @ 12,500 rpm Maximum torque 112.7 Nm (11.5 kg-m) @ 10,000 rpm

118.3 Nm (12.1 kg-m) @ 10,000 rpm Starting system Electric Lubrication wet sump Carburettor/Fuel supply Fuel injection Clutch type Wet multiple-disc coil spring Ignition system T.C.I Primary / Secondary reduction ratio 3.042 / 3.000 Transmission type Constant mesh, 6-speed Final transmission Chain

Yamaha FZS


Engine type Air-cooled, 4-stroke, SOHC, 2-valve Displacement 153.0cm3 Bore & Stroke 58.0 × 57.9mm Compression ratio 9.5:1 Maximum output 14PS / 7500 rpm Maximum torque 14 N.m / 6000 rpm Starting method Electric starter Lubrication type Wet sump Carburetor type BS26 Clutch type Constant mesh wet multiplate Ignition type CDI Primary/secondary reduction ratio 3.409 / 2.857 Transmission type Return type 5-speed Fuel tank volume 12 liters Engine oil volume 1.2 liters

Yamaha FZ16


Engine type Air-cooled, 4-stroke, SOHC, 2-valve Displacement 153.0cm3 Bore & Stroke 58.0 × 57.9mm Compression ratio 9.5:1 Maximum output 14PS / 7500 rpm Maximum torque 14 N.m / 6000 rpm Starting method Electric starter Lubrication type Wet sump Carburetor type BS26 Clutch type Constant mesh wet multiplate Ignition type CDI Primary/secondary reduction ratio 3.409 / 2.857 Transmission type Return type 5-speed

Yamaha Fazer



Displacement 153.0cm3

Maximum power 14PS / 7500 rpm

Maximum torque 14 Nm / 6000 rpm

Starting system Electric start

Fuel tank capacity 12 litres

Transmission type Return type 5-speed

Yamaha MT01


Engine type Air-cooled 4-stroke, V-twin, OHV,4 valves per cylinder

Displacement 1,670 cc Bore & Stroke 97.0 x 113.0 mm Compression ratio 8.4:1 Maximum power 66.3 kW (90 PS) @ 4,750 rpm Maximum torque 150.3 Nm (15.3 kg-m) @ 3,750 rpm Carburettor/fuel supply Twin-bore, Electronic Fuel Injection Starting system Electric Lubrication Dry sump Clutch type Wet, multiple disc Ignition system T.C.I Transmission type Constant mesh, 5-speed Final transmission

Chain



Displacement 153.0cm3

Maximum power 14PS / 7500 rpm

Maximum torque 14 Nm / 6000 rpm

Starting system Electric start

Fuel tank capacity 12 litres

Transmission type Return type 5-speed

Yamaha MT01


Engine type Air-cooled 4-stroke, V-twin, OHV,4 valves per cylinder

Displacement 1,670 cc Bore & Stroke 97.0 x 113.0 mm Compression ratio 8.4:1 Maximum power 66.3 kW (90 PS) @ 4,750 rpm Maximum torque 150.3 Nm (15.3 kg-m) @ 3,750 rpm Carburettor/fuel supply Twin-bore, Electronic Fuel Injection Starting system Electric Lubrication Dry sump Clutch type Wet, multiple disc Ignition system T.C.I Transmission type Constant mesh, 5-speed Final transmission

Chain

HEAT ENGINES HEAT ENGINES

Any type of engine or machine which derives heat energy from the combustion of fuel or any other source and converts this energy into mechanical work is termed as a “heat engine”.

FUEL MECHANICAL WORK

Classification of heat enginesClassification of heat enginesExternal Combustion Engines. Internal Combustion Engines.

External Combustion EnginesAn external combustion engine (EC engine) is a heat engine where a working fluid is heated by combustion of an external source, through the engine wall or a heat exchanger. The fluid then, by expanding and acting on the mechanism of the engine produces motion and usable work. The fluid is then cooled, compressed and reused (closed cycle), or (less commonly) dumped, and cool fluid pulled in (open cycle air engine).

Stirling Engine

HEAT ENGINES

Gas Turbine. Steam Turbine

Internal Combustion EnginesThe internal combustion engine is an engine in which the combustion of a fuel occurs with an oxidiser (usually air) in a combustion chamber. In an internal combustion engine the expansion of the high temperature and pressure gases, that are produced by the combustion, directly apply force to a movable component of the engine, such as the pistons or turbine blades and by moving it over a distance, generate useful mechanical energy

Petrol Engines Diesel Engines

CLASSIFICATION OF I.C. ENGINES

1. According to cycle of operation: Two-stroke cycle engines. Four-stroke cycle engines.

2. According to cycle of combustion: Otto cycle engine (combustion at const volume). Diesel cycle engine (combustion at const pressure). Dual combustion cycle.

3. According to cylinder arrangement: Horizontal engine Vertical engine V-type engine Radial engines

4. According to their uses: Stationary engine Portable engine Marine engine Automobile engine Aero engine

5. According to method of ignition: Spark ignition

Compression ignition

6. According to method of cooling: Air cooled engine Water cooled engine

7. According to no. of cylinders: Single cylinder engine Multi-cylinder engine

8. According to speed of engine: Low speed engine Medium speed engine High speed engine

DIFFERENT PARTS OF I.C. ENGINES

A. Parts common to both Petrol and Diesel engine:

1. Cylinder 2. Cylinder head3. Piston 4. Piston rings5. Gudgeon pin 6. Connecting rod7. Crank 8. Crankshaft9. Engine bearings 10. Crankcase 11. Flywheel 12. Governor13. Valves and valves operating mechanism.

B. Parts for Petrol engine only:1. Spark plugs2. Carburettor or MPFI System3. Fuel pump

C. Parts for Diesel engine only:1. Fuel pump 2. Injector

MPFI (Multi Point Fuel Injection)

In this system each cylinder has number of injectors to supply/spray fuel in the cylinders as compared to one injector located centrally to supply/spray fuel in case of single point injection system.

Multi-point fuel injection injects fuel into the intake port just upstream of the cylinder's intake valve, rather than at a central point within an intake manifold, referred to as SPFI, or single point fuel injection. MPFI (or just MPI) systems can be :Sequential, in which injection is timed to coincide with each cylinder's intake stroke.

Batched , in which fuel is injected to the cylinders in groups, without precise synchronization to any particular cylinder's intake stroke.

Simultaneous , in which fuel is injected at the same time to all the cylinders.

ENGINE PARTS

Cylinder HeadIn an IC engine, the cylinder head sits atop the cylinders and consists of a platform containing part of the combustion chamber and the location of the valves and spark plugs.

Spark PlugThe spark plug ignites the air/fuel mixture inside the cylinder.This occurs when high voltage, triggered at precisely the right instant, bridges the gap between the center and the ground electrodes. The end result is an even burning of the air/fuel mixture inside the cylinder. The spark plug also provides a secondary purpose of helping to channel some heat away from the cylinder.

RockerArm The rocker arm is a reciprocating lever that conveys radialinformation from the cam lobe into linear information at the poppet valve to open it. One end is raised and lowered by the rotating lobes of the camshaft (either directly or via a lifter (tappet) and pushrod) while the other end acts on the valve stem. When the camshaft lobe raises the outside of the arm, the inside presses down on the valve stem, opening the valve. When the outside of the arm is lowered by the camshaftthe inside rises, allowing the valve spring to close the giver.

Combustion Chamber A combustion chamber is the part of the engine in which fuel is burnt.

Valves Valves let air in and exhaust out.IC engines use poppet valves to allow air to flow through the cylinder head andexhaust gases out.Seating of the valve faces against insert sealing surfaces seals the combustion chamber.

HeadGasket It is a gasket that sits between the engine block and cylinderhead in an internal combustion engine. Its purpose is to seal the cylinders to ensure maximum compression and avoidleakage of coolant or engine oil into the cylinders; as such, itis the most critical sealing application in any engine, and as part of the combustion chamber, it shares the same strength requirements as other combustion chamber components

Cylinder Block The cylinder block or engine block is a machined casting (or sometimes an assembly of modules) containing cylindrically bored holes for the pistons of a multi-cylinder reciprocating internal combustion engine.A wet liner cylinder block features removable cylinder bores which fit into the block by means of special gaskets and offer the advantage of being easily replaced without the need to re-machine the entire casting.

Piston A piston is a component of reciprocating engines, pumps andgas compressors. It is located in a cylinder and is made gas-tight by piston rings. In an engine, its purpose is to transferforce from expanding gas in the cylinder to the crankshaft via apiston rod and/or connecting rod.

Piston Rings A piston ring is an open-ended ring that fits into a groove onthe outer diameter of a piston in a reciprocating engine such asan internal combustion engine or steam engine.It includes twocompression rings and one oil ring.

Gudgeon Pin The Gudgeon Pin serves to connect the piston to theConnecting rod. It passes through the pin bosses in the piston

and the upper end of the connecting rod . The piston pin must be hard to provide the desired wearing qualities

Cylinder LinerThe circular housing that the piston moves in when the Cylinder is not an integral part of the block. Also known as a "Sleeve”.

Connecting Rod In a reciprocating piston engine, the connecting rod or conrod connects the piston to the crank or crankshaft.The small end attaches to the piston pin.The big end connects to the bearing journal on the crank throw, running on replaceable bearing shells.

CrankcaseIn a piston engine, the crankcase is the housing for the

crankshaft. The enclosure forms the largest cavity in the engine, separated from the cylinders by the reciprocating pistons. Besides protecting the crankshaft and connecting rods from foreign objects,the crankcase serves other functions, depending

on engine type.

Crankshaft Sometimes casually abbreviated to crank, is the part of an engine which translates reciprocating linear piston motion into

rotation. To convert the reciprocating motion into rotation, the crankshaft has "crank throws" or "crankpins",

additional bearing surfaces whose axis is offset from that of the crank, to which the "big ends" of the connecting rods from each cylinder attach.

Camshaft The camshaft is an apparatus often used in piston engines to

operate poppet valves. It consists of a cylindrical rod running the length of the cylinder bank with a number of oblong lobes or cams protruding from it, one for each valve. The cams force the valves open by pressing on the valve, or on some intermediate mechanism, as they rotate.

Flywheel A flywheel is a rotating disc used as a storage device for

kinetic energy. Flywheels resist changes in their rotational speed, which helps steady the rotation of the shaft when a fluctuating torque is exerted on it by its power source such as a piston-based (reciprocating) engine

Sump Tank

The sump surrounds the crankshaft. It contains some amount of oil, which collecting the bottom of the sump (the oil pan).

.

ENGINE GLOSSARY

Stroke :

Single direction movement of the piston, when the piston moves up from BDC to TDC or TDC to BDC, the single direction movement of the Piston in one direction is called 'Stroke'.

Bore: The bore is inside Diameter of Cylinder

RPM: Revolution per minutes

Effect of bore and stroke on engine performance: Engines of the same displacement vary in character depending on "bore and stroke".Short stroke engines: Stroke is smaller than bore diameter.Square engines: Stroke and bore diameter are even.Long stroke engines: Stroke is larger than bore diameter.

Compared with a long stroke engine, the square or short stroke type is easy to raise the engine speed and develop high power. If the engine speeds are the same, the piston speed is slower and friction resistance can also be reduced. Among other merits are the lower overall height and compact design. Therefore, the square type and short stroke engines are dominant.

Displaced Volume : .

Combustion Chamber volume: The volume of space between the cylinder head and the piston at TDC is called "combustion chamber volume".

Compression ratio:

The compression ratio indicates to what extent the air - fuel mixture is compressed when piston is at TDC in compression stroke.The higher Compression ratio is used for High speed Vehicles.

Compression Ratio :

Volume of Combustion chamber (v) + Displacement (v) divided byVolume of Combustion chamber (v)

Torque: The turning force exerted on rotating parts is called “torque”. Motorcycles are driven by the torque of the crankshaft.

Torque = Force × distance (kg·m N·m = kgN × m)

Change in torque (Primary and secondary reductions ,and speed reduction from the gear box).

The greater the number of gear teeth, the greater the torque. However, the rotational speed is reduced.

The “maximum torque” is indicated along with the engine speed at which maximum torque is delivered.

When a motorcycle is run at maximum torque, the rear wheel driving force is at the maximum.

Difference between BHP (Brake Horse power) & PS (Pfred Scale ) :

Both are the unit of Power

1 Bhp = 1.0143 Ps

Single Over Head Cam Shaft (SOHC ) : In this type of Cam Mechanism, Cam shaft is positioned in the cylinder head & driven by Cam Chain to operate Inlet & exhaust valve thru Rocker arms.

In this type mechanism Lesser parts are used to operate valves hence operation is stable even at high speed.

Trochoid Type Oil Pump : Two rotors rotating at different Speeds causing variations in the volume between them. This Variation in volume causes oil flow in and out of the Pump. The Trochoid Pump is more commonly used due to its advantages and compact design.

Four Stroke Engine:

Basic construction: A 4-stroke engine requires two complete revolution of the crankshaft (4 strokes of the piston) to complete a full cycle (Intake, Compression, Combustion and Exhaust).

Power stoke: A power stroke takes place on every other full rotation of the crankshaft. The cylinder head has two ports. An intake and an

exhaust. Valves control the opening and closing of these ports. The opening and closing of the valves is timed to piston movement and location in its travel.

All air/fuel mixture compression takes place above the piston.

Advantages: Intake, compression, combustion and exhaust occur independently, so operation is more precise, efficient and very stable.Fuel loss caused by "stroke" over lap is less than 2-stroke. Fuel consumption is lower.

Single Axis Balancer

As engine runs, vibrations are caused from inertia force created by motion of engine Components (Piston & Connecting rod).

In order to lessen the vibration a balancer weight is added on a axis positioned at an angle above Crank Shaft and made to rotate in the opposite direction of Crank Shaft to reduce engine vibrations.

Wet Sump system : Oil is stored in the oil sump in bottom of crank case, from here oil is pumped under pressure to various parts of the Engine. Oil is fed to both the Crank Shaft & Valve Train.

The Crank Shaft assembly is lubricated with the same oil used to lubricate the Transmission & Clutch .The oil is fed directly from the Oil Pump. The Cylinder & Piston are lubricated by splash oil that previously lubricated the Crank pin & connecting rods. The Valve Train is also lubricated by Pressure fed oil. After lubrication , the oil returns to the sump (Oil Chamber).

Diamond Frame: In this type of Frame the Engine is mounted at five locations (One at the top & two each at the front & rear of the Crank cases) and used as a stressed member of the frame for better stability, less vibrations & light weight The large size & thickness of the main pipe provide extra rigidity.

BS type Carburetor

The BS carburetor (‘B’ stands for butterfly valve and ‘S’ for SU, designating the maker Skinner Union.)

In this type of the Carburetor, the air-fuel mixture is controlled by the regulation of the Engine Intake vacuum (negative pressure) which results in smooth operation of the vehicle, stable idling & good fuel economy.

Also due to this carburetor, the user gets smooth acceleration, even if the rider opens or closes the throttle sharply.

YTPS Technology

Yamaha Throttle position sensor (YTPS) is a unit fitted on the carburettor on same axis of Butterfly valve.

It is adopted in order to control the ignition timing for each engine RPM. This helps to ensure excellent combustion efficiency and hence smooth throttle response, superior fuel economy and less emissions.

With the use of YTPS technology, 3- dimensional digital mapping has been done among, engine revolution, ignition timing and throttle opening for optimum combustion their by ensuring maximum mileage.

Documents

Yamaha Project Machining