Written by Engine Systems
Engine Block
| Component | Specifications | Functions |
|---|---|---|
| Cylinder Block | Materials: Aluminum/Iron, Configurations: Single/Twin/V/Inline, Bore sizes: 60-110mm, Compression ratios: 9:1 to 13:1 | Houses pistons and cooling channels |
| Pistons | Materials: Forged/Cast aluminum, Compression heights: 25-35mm, Ring configurations: 2-3 rings, Coatings: Teflon/Moly | Convert combustion pressure to mechanical motion |
| Connecting Rods | Materials: Steel/Titanium, Lengths: 120-160mm, Bearings: Plain/Roller, Weight: 250-400g | Connect pistons to crankshaft |
| Crankshaft | Materials: Forged steel, Configurations: Single/Multi-pin, Balancing: Internal/External, Stroke lengths: 45-80mm | Converts reciprocating to rotary motion |
Valve Train
| Component | Specifications | Functions |
|---|---|---|
| Camshafts | Lift: 8-12mm, Duration: 240-300 degrees, Materials: Hardened steel, Profiles: Sport/Touring | Controls valve timing and lift |
| Valves | Materials: Steel/Titanium, Sizes: Intake 24-40mm/Exhaust 20-35mm, Stem diameter: 4.5-7mm, Angles: 30-45 degrees | Control gas flow in/out of cylinders |
| Valve Springs | Materials: Chrome silicon, Pressure ratings: 60-120 lbs, Coil count: 6-10, Natural frequency: 5000-8000 Hz | Maintain valve closure |
| Rocker Arms | Materials: Steel/Aluminum, Ratios: 1.5:1 to 2:1, Bearing type: Needle/Ball, Adjustment: Screw/Hydraulic | Transfer cam motion to valves |
Fuel System
Fuel Delivery
| Component | Specifications | Functions |
|---|---|---|
| Fuel Injectors | Flow rates: 200-400cc/min, Pressure: 40-60 PSI, Spray patterns: 4-12 holes, Response time: 1-2ms | Atomize fuel into cylinders |
| Fuel Pump | Flow rate: 50-100 L/hr, Pressure: 3-5 bar, Type: Electric/Mechanical, Power draw: 3-5 amps | Deliver fuel from tank to injectors |
| Throttle Bodies | Bore sizes: 36-54mm, Type: Single/Multi, Control: Electronic/Cable, Sensors: TPS, MAP | Control air intake volume |
| Air Filter | Material: Paper/Cotton/Foam, Flow rate: 200-400 CFM, Size: 8-12 inches, Filtration: 10-30 microns | Filter incoming air |
Transmission System
Gearbox
| Component | Specifications | Functions |
|---|---|---|
| Gears | Material: Case-hardened steel, Types: Helical/Straight cut, Ratios: 1st: 2.5-3.0:1, 6th: 0.8-1.0:1, Width: 12-20mm | Transfer power through transmission |
| Shift Drum | Material: Hardened steel, Groove pattern: Helical, Positions: 5-6 speed, Indexing: Positive stop | Controls gear engagement |
| Shift Forks | Material: Steel/Bronze, Type: 2/3 prong, Travel: 6-10mm, Thickness: 5-8mm | Move gear selectors |
| Main Shaft | Material: Hardened steel, Diameter: 20-30mm, Bearing type: Ball/Roller, Spline count: 20-30 | Supports primary drive gears |
Final Drive
| Component | Specifications | Functions |
|---|---|---|
| Chain Drive | Size: 520-532, Strength: 5000-9000 lbs, Link count: 110-130, Type: O-ring/X-ring | Transfers power to rear wheel |
| Sprockets | Material: Steel/Aluminum, Front teeth: 14-17, Rear teeth: 38-48, Pitch: 15.875mm | Drives chain and changes ratios |
| Belt Drive | Width: 20-30mm, Teeth: 128-158, Material: Kevlar reinforced, Tension: 45-85 lbs | Alternative power transfer method |
| Shaft Drive | Material: Steel, Diameter: 25-35mm, Gear ratio: 2.5-3.0:1, Lubrication: Hypoid gear oil | Enclosed power transfer system |
Braking System
Front Brakes
| Component | Specifications | Functions |
|---|---|---|
| Calipers | Piston count: 2-6, Piston size: 25-34mm, Mount: Radial/Axial, Material: Aluminum alloy | Apply braking force to discs |
| Discs | Diameter: 300-330mm, Thickness: 4.5-6mm, Material: Stainless steel, Type: Floating/Fixed | Provide braking surface |
| Master Cylinder | Bore size: 14-19mm, Stroke: 15-20mm, Ratio: 1:1 to 1:1.5, Material: Aluminum | Generates hydraulic pressure |
Rear Brakes
| Component | Specifications | Functions |
|---|---|---|
| Caliper | Piston count: 1-2, Piston size: 30-38mm, Mount: Fixed, Material: Aluminum alloy | Apply rear braking force |
| Disc | Diameter: 220-270mm, Thickness: 4-5mm, Material: Stainless steel, Type: Fixed | Rear braking surface |
| Brake Lines | Material: Steel braided/Rubber, Pressure rating: 1500-2000 PSI, Inner diameter: 3-4mm, Length: Vehicle specific | Transfer brake fluid pressure |
Electrical System
Power Generation
| Component | Specifications | Functions |
|---|---|---|
| Alternator | Output: 300-500W, Voltage: 14.4V, Type: 3-phase AC, Speed range: 1000-10000 RPM | Generates electrical power |
| Battery | Voltage: 12V, Capacity: 8-18Ah, Type: Lead acid/Lithium, Cold cranking amps: 100-200 | Stores electrical energy |
| Regulator/Rectifier | Voltage regulation: 13.8-14.8V, Current capacity: 30-40A, Type: MOSFET/SCR, Cooling: Air/Oil | Controls charging system |
Electronics
| Component | Specifications | Functions |
|---|---|---|
| ECU | Processing speed: 100-400 MHz, Memory: 512KB-2MB, Inputs: 16-32 channels, Outputs: 8-16 channels | Controls engine management |
| Sensors | Types: O2/TPS/MAP/CKP/IAT, Voltage range: 0-5V, Response time: 1-10ms, Accuracy: ±1-3% | Monitor engine parameters |
| Lighting | Headlight: 35-65W LED/HID, Tail light: 5-10W LED, Turn signals: 10W LED, Position lights: 5W LED | Provide illumination |