Design and Development of a Lightweight, High Performance 1.0litre 4-Stroke Engine for Recreational Products

Jonathan Saunders; Patrick Walker

doi:10.4271/2003-32-0027

2003-09-16

Design and Development of a Lightweight, High Performance 1.0litre 4-Stroke Engine for Recreational Products 2003-32-0027

In anticipation of the ever tightening exhaust emissions regulations for recreational and off highway vehicles, Maxsym has undertaken the design of a new generation of 4-stroke engines. These engines are specifically designed to combine the proven low emission capabilities of a 4-stroke engine with comparable or better power, weight, cost, and package size to a 2-stroke engine.

The benchmarks for this project were two sizes of 2-stroke engine that are used in high performance recreational vehicles. 600cc and 900cc 2-stroke engines with power outputs of around 105bhp and 150bhp respectively were analysed, and the weight and package size were recorded.

Following the design and development of a 996cc parallel twin cylinder base engine, two variants using mainly common components were produced. A naturally aspirated engine generating 120bhp and a turbocharged engine of 195bhp. Both base engines weigh 71lbs, the turbo having an additional 48lbs associated with the turbocharger and manifolds. A package size for the base engine of only 300mm long × 470mm tall × 230mm wide makes for a very compact engine ideally suited to markets such as personal watercraft (PWC), snowmobiles, motorcycles etc..

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Design and Development of a Lightweight, High Performance 1.0litre 4-Stroke Engine for Recreational Products 2003-32-0027

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