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    Classic-2-Stroke Tuners Handbook PDF

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    greaternorthroad8820

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    Two-stroke TUNERT HanPBOOK CORO FUNDAMENTALS Airey CLO BSLV | bes dm iN 1D) 3545] 1.) Bhs) EXPANSION CHAMBERS CYLINDER SCAVENGING PORT TIMING CRANKCASE PUMPING CARSURETION, IGNITIO: i i | Two-stroke TUNER’S HANDBOOK by Gordon Jennings lustrations by the author ty meena Copyright 81973 by Gordon Jennings FOREWORD ten years ago th two-stroke engine was widely and q thought to be a understandably having substantial theoreti stroke for each 360 degree: dual power the output end of the e some of the theoret promise, as it delivered a power Ikshafe rotation but the hard reality was that sunt to mich when totalled at i to persist i rts to wring competitive m the racing two-stroke engine. To say that they were ultimately ssful would be gross understatement. "Those engineers were motivated by the need to demonstrate that the two-stroke ddo wonders for hundreds of dol ngg may be altered simply by reshaping the holes in its ower output markedly resonant effects in its intake and exhaust tracts, ications are costly, hhand, while the two-stroke engine does not commonly require large dollar inputs to raise its power output, it does require an in-depth under- ‘on the part of the man doing the is. In an attempt to acquire that understanding I began a study of the hig itput tworstroke we that has led to the collection of a minor order costs 3 less satisfactory € such as the general behavior of ex flatter myself to think tha book for the guidance of # at least take care of # 3t supply all of the prevent the ‘My special thanks to Mr. Joh ineering, who has done much to dilute my once pure i uld not be held accountable for the residue found herein). Also to the late Henry Koepke, who mistakenly assumed that I knew somethi stroke engines and supported my early why started needled, pleaded, com publishable form, Thammered my file of notes into CONTENTS Contents... FUNDAMENTALS: Predicting Power Piston Speed .... Piston Acceleration CRANK TRAIN «.. ‘The Piston Piston Rit Wristpin/Crankpin Crank Assembly CYLINDERHEADS o ‘The Combustion Process ‘Squish Bands Plug Location .. Head/Cylinder Sealing EXPANSION CHAMBERS ‘The Basic Process “Tuned Length .. Diffuser Proportions Baflle Cones Outlet Pipes Lead-in Pipes ae Expansion Chamber Design Formulae. se 73. PORT TIMING 5 Specific Time-Area 76 Angle-Atea eo. a eee 80, Time-Area Combinations 81 Emphasis on Area . ce vn 84 Timing Limits ... a sone 85 Rotary-Valve Timing or) ORANKCASE PUMPING sent 1 Resonance Elects... somes OB Carburetor Location... a - 94 Crankease Volume 95, Reed Valves 98, ‘The Rotary Valve 101 Intake Port Shape 102 CYLINDER SCAVENGING Exhaust Port Port-Edge Chamfers CARBURETION, IGNITION Spark Plugs 105 109 12 15 ug 1h 129 130 1st 143. 152 FUNDAMENTALS Throughout this book it wi inconvenient though that assumption. 's progressed to at least 1 superficial piston-type internal cos bustion engine —with particular reference to those operating on the two-stroke cycle principle—converts quantities of fue! at the end of its crankshaft. People who need enlightenment in that regard will find a wealth of ex {erature collected on the shelves of any ‘and physics re is an entirely kind of “state of engines for laymen—\ h-output tworstroke Jost cases do not have access to the literature amounts of time and money return appropriate to the i iake you a Kade ‘more serious mistakes. ‘The first serious mistake a lay that those who designed what they were d& jon to be provided here 0; it will help you to avoid some of the © is to assume ne didn’t know , the professional engineer knows very an what the experi engines are compromised, interest of manufacturing ports may derive their shape experimenter can manufacturing, Si designing for mass cs engine must be agreeable to many different uses — even though that inevitably aly well. In these areas toa very specific loring process one inevitably all the various expenses the engine's designer has avoided. Hours of labor may be required to finish rough-cast ports; dollars will be spent correcting other things that are the creatures of manufacturing economies; power added at reased speeds required to obtai be paid for in terms of reliability Two Stroke TUNER’s HANDBOOK Another mistake commonly made, sometimes even by enjoyed some odifying two-stroke engines, it any given displacement erage pres der during the power stroke and power strokes occur, minus work absorbed by friction and scav and pumping losses, and the engine's net output there are speeds, and in inertia ngineer ing losses can be gh an engine—with a properly Some improve nut the scope f ‘complished with engine is ely to be, monly know crown area, Thus, measurements being FUNDAMENTALS tor of performance an modified engi PREDICTING POWER psi—an improvement yield a 64-percent increase in power output without raising the 64-percent increase in operating speed have the same effect on out following formula for calculating horsepower: Ps Ware mi TD? S-2-ng a Dae g,m Pris MEDELSVER~ TAY Ce NY S? SLAGLANGD, mM Re VARY, P/mnin ReANTAL CYL, AB Bers PERI. brake mean effective pressure, in psi Lis piston stroke, A is the area of one pi apa lot easier to increase the Jatter than the former. As already stated, 1 figures for engin effectively) for maxi ing arranged solely (and m horsepower at peak revs would be about 115 psi— highly-devcloped two-stroke engines operating up at 125 psi, ‘The exact ni and the width of an with, cylinders vice versa, Road ra d to exert a maximum effort over a very narrow speed range, will usually show a bmep of 100-115 psi, and of course the same remarks regarding the influence of ess beyond the mere sa mn of vulgar 30,5 Two Stroke TUNER’s HANDBOOK they may be used very profitably to determine an engine's suitability ticular application. For example, they shed light on the future nsform Kawasaki's F-5 “Bighom” ination in road racing. Much has been made, by the Kawasaki’ supporters, of the usefulness of a broader power range inherent with the F-5's disc-valve induction and the 100ce advantage it gets, over the TD-2, by having only a single cylinder (this, under the present American Motorcycle Association rules). Now while it is, reycle having a wide power band is easier for its rider to manag offer an absolute if very slight advantage on short, extraordinarily fwisty circuits, one must not overlook the fact that the TD-2 has been blessed with an excellent transmission jumber of riders quite capable of coping with troduced by the need for frequent gear changes. Viewed any serious challenger to Yamaha's supremacy which horsepower must be met with horsepower. And what are the Kawasaki's prospects of developing that kind of horsepower? Let's have @ e numbers ‘Assuming that the man who modifies the Kawasaki F-5 knows his business, but doesn't have all the development time in the world, (probability favors the latter far more than the former) then he very likely will arrive at a combination of porting, etc., good for a bmep of about 105 psi—which is about all that can be expected with a single cylinder of 350ce displacement, To expect more would be to ignore the considerable difficulties in scavenging efficiently the F-5’s large-bore (3.17-inch) cylinder, Further assuming (and tas we shall see later, this assumption is far from safe) that the F-5 engine will remain in one, working piece for the duration of a longish race with its rider observing a red-line of 9000 rpm, with a power peak at 8500 rpm, then, 105 x 993 x 7.89 x 8500 33,000 BHP = BHP = 47.6 So, a well developed F-5 would deliver 47.6 brake horsepower. How does that compare with the Yamaha TD-2? With all the years that have gone into the TD.2's development, and giving due thought to Yamaha's proven expertise in these matters, it seems safe to assume that this engine would be operating with a bmep of 115 psi at its power peak—which seems to be at 11,000 rpm. ‘working from those numbers and the 250ce Yamaha twin’s bore/stroke dimensions of 56mm and 50mm, respectively, 115 x 164 x 3.81 x 22,000 33,000 BHP = BHP = 480 FUNDAMENTALS e who wor d try to beat the Yamaha with a Kawasakt Ives a task of considerable magnitude. The only re 0.4 bhp down they probably we horsepower, figured from the moment those for peak horsepower w for a change to the next higher F-5 have taken upor Dright spo! single- vis going to be stressed very near its absolute limit—a limit imposed the properties of av not only extremely diffic requires data concerning, rooms of the factories guide-lines which, 2 ‘A quick and e by worki do not trav: they move from a dead stop at each end of their stroke, maximum speed that often is in excess of 120 mph, and then brake to another co we use just the mean piston speed and the sa t, for engines having bore-stroke di for motorcycles, isabout 4000 casily by applying the following formula: 20 m/s, sions and red-lined at 80.5/6%.9] Two Stroke TUNER’s HANDBOOK FUNDAMENTALS Cu = 166xLN a reduction in bore, and with it a loss of piston area against ‘which re Cui ct per mimute pressure can exert its force, that exactly balances the loss of Lis short-stroke engine (which is, in turn, compensated by Nis lutions per minute The only thing wrong with the long-strol s crankshaft speed is limited by inertia loadings, and that in turn limits its absolute power potential as compared with the “modern” short-stroker. On the other hand, it is compensated by having a much more compact combustion chamber, which makes for more efficient burning, and by lower thermal loadi C., = 166 x 2.68 x 9000 the piston as a result of the smaller crown area into which heat fror C,, = 4000 ¢/min ‘combustion process may soak. Finally, there is an advantage in port area for Bsns VID 9008 > 12.5 mm) an piston speed, in in direct proportion to stroke, butis increased by a factor of 3.14 (the constant, pi) with enlargements in bore. These arc very real advantages, but they are not enough, usually, to prevail against the short-stroke engine’s sheer ability 1g abruptness if pressed to rev. Ci ig subject to much juggling in the hat few engines, the F-5 not horsepower jore potent factor in d ing power an piston speeds of output than the nprovements in bmep obtainable with the ‘marginally better combustion chamber and porting in the long-stroke engine. A 10-percent improvement in our Kawasaki F-5 engine's bmep (a large improvement indeed) would at to 52.8 bhp; leave the bmep at takes an engine ichanged, but sho 1d spin it 11,000 rpm and you would have cd the ground between 3500 ft/min and 61.3 bhp. There is indeed no substitute for revs : s covered with unpleasant possibilities, n of materials and 4000 ise its VAS m/s into the twilight zone of reliabilit 20.35m/ the near absolute limit of 4000 ft/ mized with the proper select note here that there are exceptions to this rule among PISTON ACCELERATION -d, long-stroke engines, which tend to have very light (and strong) reciprocating parts relative to their absolute stroke. An example Sadly, while there is no substitute for revs, there are plenty of barriers: that comes to mind is the Bultaco 125ce TSS, which had a stroke of no less piston speed is one, as was already noted. But that is a rather indirect limit es (decidedly long for a 125) but which would, in “factory” asit ignores the fact that itis not speed so much as all the starting and stopp of pistons that does the damage, or at least the worst of any damage. The and that represents a mean piston speed of acceleration forces generated by the starting and stopping are felt even in an the opinion that the resulting thinnish engine's earings, but they 1 connecting rod and piston disastrous effect on the latter, as any attempt to make so to make it heavier~which aggravates the very hould improve. Even so, an engine's es heel, the problem that may most strongly resist solution, often Je engines in many is the disastrous effects piston acceleration may have on the piston's rings. npared Itoften is thought, and quite wrongly, that rings maintain a seal between the piston and the cylinder’s walls simply through their properties as springs. ht should convince you that such cannot be the case, for most ressed in the process 0 a t their TSS never was as predictably 1d have a particular! me crankshaft speed (11,500) a piston stronger i wn piston speed of only 3775 ft/ While on th of bore/stroke there is much in favor of long stroke two-stroke applications. They are not superior (as many people seem to thi ay short-stroke designs in terms of low-speed tora) bore/stroke rings, con Norden, (8% nmin st Two Stroke TUNER’s HANDBOOK groove in the groove) shoves s pressures holding nears the top FUNDAMENTALS described instantly spping back into its groove again—to repeat ly stopped and the ring’s span of several degrees of te of its groove; a more serious case is failure, overheating, and piston seizure. n be avoided, thanks to the work of ie ring flutter itis opposed by a. id in consequence has sare high enow, the following feet per second squared imute To illustrate how high let's use as an example the Yamaha TD-2, using 11,000 rpm for N. The formula tells us that Two Stroke TUNER’s HANDBOOK FUNDAMENTALS the answer rounded th paper and pencil) no less that the acceleration remains not o the TD-2 engine, comparativ 000 ft/sec? —but not much higher, ing ring thicknesses and the accelera- are discussed elsewhere appropriate here, After establishing ring, which has ‘groove in the piston. Thi its horize around th tter-resistant by the fact that ;, as compared to clearances top center that is most us. ‘you, for example, how much to raise the top ed 1g rattled about vigirously and if the kes ring, and the groove trying to , its ability to seal ng enough, the ; both beco: Two Stroke TUNER’s HANDBOOK {in degrees and in piston travel from top center. You may devise your own methods for deriving information according to your preference and resources; I have explained my own techniques elsewhere in this text, in the appropriate chapters. ‘An item that must be included applies at specific points throughout the engine and its related I be covered later, but you should know a few of the funda- mentals now, and thus save me from becoming influenced by gas which it forms, as shape of the surface, Please understand that "with general flow throughout its depth — novement increasing as to distance from the surface on which it is formed. And as close as .020-inch from the surface, flow may still be in the order of 80-percent of t idstream, which 1¢ restriction formed by the boundary not very great. ig from the shape thick boundary layer, In straight, paral y, transfer ports should diminish in cross- sectional area from their entrance in the crankcase toward their outlet in the cylinder, These gases a ‘motion; when at rest they resi this means that there al FUNDAMENTALS the movement of compensated toward the the crankease has risen the port—bu separately. ‘These inertia effects are usel

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