TWO WHEELER TECHNOLOGY

CHAPTER – 1

FRAMES, BODY AND TRANSMISSION SYSTEM

1. State function of frame and list the types of it. (S-15) (W-16)(S-18)
ANS :
Function of frame:
1) It acts as a beam supported by the wheels to carry the weight of the propelling machinery and
the rider.
2) It provides a non-flexing mount for the engine suspension and wheel.
3) It provides free steering movement of the front wheel.
Types of frame: motorcycle/ Mopeds use three basic frames
1) Cradle-single cradle and double cradle frame
2) Backbone frame
3) Tubular frame-single down tube using engine as stressed member
4) Stamped frame

2. List four major frame components and write function of each. (W-15)
ANS :
Major frame components:
1. Bottom tube
2. Steering head tube
3. Swing arm mount
4. Seat rail
5. Down tube
6. Seat pillar tubes
7. Main tube.
Function of major frame components:
1. Bottom tube: It acts as a beam supported by the wheels to carry the weight of the propelling
machinery and the rider.
2. Steering head tube: It provides free steering movement of the front wheel.
3. Swing arm mount: It provides a non-flexing mount for the engine suspension and wheel.
4. Seat rail: It carry & support load of rider & pillion rider
5. Down tube: It provides structural strength to the steering head tube & bottom tubes.
6. Seat pillar tubes: It provides structural strength to the seat rail & main tube.
7. Main tube: It supports fuel tank assembly.

3. What are the types of two wheeler frames? Explain any one. (S-17)
ANSWER :
Types of frame:
Motorcycle/ Mopeds use three basic frames
1) Cradle-single cradle and double cradle frame
2) Back Bone frame
3) Stamped frame

1.Cradle-single cradle and double cradle frame:

The Cradle frame is distinguished by a pair of more or less parallel tubes within which the
engine and gear box rest. This design derives its strength from triangular form of the support
tubing. In Large high powered vehicles, additional support may be provided by gussets to
increase the rigidity of frame. A cradle frame may one tube or two tube can be seen.

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.
2. Back Bone frame
In the Back Bone frame, the engine hangs from the top of the frame and acts as a structural
member. This design requires the frame to be relatively heavy to provide adequate strength. Since
the engine is not now enclosed by the lower frames tubes, the engine service becomes simplified.

3. Stamped frame :

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Usually consists of two pieces of stamped sheet metal that are welded together .Frame strength in
this design is achieved by the shape of stamping. A stamped frame is least expensive to produce. It
is normally used on inexpensive, small displacement motor cycles and moped

4. Describe with sketch single down- tube type frame using the engine as stress member.
(S-16)
Answer:
Single Cradle Frame- The single cradle is the simplest type of motorcycle frame, and looks
similar to the first ever motorcycle frames. It is made from steel tubes that surround the engine
with a main tube above and other, smaller diameter tubes beneath. If a single cradle becomes
double at the exhaust, as frequently occurs, it is referred to as a split single cradle frame. Single
cradle frames are usually found in off-road motorcycles.
Engines as a Stressed member: Using the engine (and gearbox in some cases) as a stressed
member of the frame (or chassis) has been used extensively on motorcycles. Manufacturers of
motorcycles with this design of frame typically attached the headstock to the upper part of their
engines; a separate frame carrying the rider and rear suspension is bolted to the rear.

5. Draw a schematic diagram of Double Cradle frame and label it. (S-15)
ANS :

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6. Describe Monocoque construction of the two wheeler body. (S-17)

ANSWER :

Monocoque is a one-piece structure which defines overall shape of the two wheeler body
while ladder, tabular provide only stress members. Today 99% two wheeler body produced in
this planet are made of steel Monocoque chassis. Chassis are made by welding of several
pieces. (Spot winding). Monocoque is made of steel. Spot-winding of monocoque construction.
Two plates are connected by resistance to electric current flow & work piece are held
together under pressure exerted by electrodes. The spot welded together by robot arm in
stream production line. This monocoque construction has Space-efficiency (the whole structure is
actually an outer shell.) Monocoque chassis has benefits of crash production because it uses a lot of
metal. It is cheap for mass production. This construction is very heavy. And this construction is
impossible for small volume production.

7. State four major components of transmission system of motorcycle and write function of
each. (W-14)(W-17)(S-18)
ANS. :
The major components of transmission system of motorcycle are
1. Clutch:
i) Clutch disengages and engages the engine to the transmission whenever required.
ii) It transmits engine power to the gear box.
iii) By using clutch we are able to shift the gears smoothly without damaging gear teeth.
2. Gear box:
i) It is used to transmit power and motion from engine to rear wheels by using clutch.
ii) Gear box provides high torque at starting and hill climbing by using lower gear.
iii) It provides various speed and torque combination by using set of gears
iv) The transmission also provides a neutral position so that the engine and the road wheels are
disconnected even with the clutch in the engaged position.
3. Drive chain and sprocket:
i) These are used to transmit a power and speed from gear box to rear wheel.
ii) By using Drive chain and sprocket we will get maximum velocity ratio.
4. Clutch lever:
i) The clutch lever is used to disengage and engage the clutch by clutch cable.
ii) it act as a leverage which further connects clutch cable to the clutch lever mechanism which
is fitted on the crank case.
5. Gear change lever or pedal:
i) It is used to shift the gear as per the driver’s requirement.
ii) It transmits the necessary power to gear drum.

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8. State types of drives used in two wheeler transmission system and give one example of
each. (S-16) (S-17)
Answer :
Types of drives used in two wheeler transmission system:
1. Gear-Driven Primary Drive: Most motorcycles use a gear-driven primary drive. This drive
system may utilize spur, offset spur or helical gears to transfer power from the crankshaft to the
clutch system. With a gear-driven primary drive system, the two gears turn in opposite directions
because each gear is on a separate shaft. This makes the clutch turn in the opposite direction of the
crankshaft. Gear- driven primary drive systems must be lubricated to prevent excessive heat caused
by the friction of the gears as the engine operates. E.g. Splendor plus Motorcycles.
2. Chain-Driven Primary Drive: The chain-driven primary drive uses a chain and two sprockets
to transfer power from the crankshaft to the clutch system. Sprockets are the teeth outside of a
wheel that engage the links of a chain. With a chain-driven primary drive, both sprockets turn in
the same direction and use either a roller chain or a Hy-Vo chain design. The Hy-Vo chain design
is the most commonly used; it is a much stronger design and quieter than the roller chain. Just like
with a gear-driven primary drive, you must keep chain-driven primary drive systems well
lubricated. E.g. Kawasaki Ninja Motorcycles.
3. Belt-Driven Primary Drive: The belt-driven primary drives system uses a toothed belt and two
pulleys with teeth attached to them. Just like the chain-driven primary drive system, the belt driven
type has both pulleys turning in the same direction. This type of primary drive is very quiet
because it uses a belt instead of gears or a chain. Unlike the other primary drive systems, you must
keep a belt-driven primary drive dry. E.g. Honda-Activa, Scooterate, mopeds.

9. Which type of clutch is commonly used in motor cycle? Justify your answer with suitable
example. (W-14)
ANS :
Multi- plate Wet type clutch is most commonly used in motor cycle because of following
reasons-
1. Multi-plate clutch is very compact, occupy less space and transmits more torque. In
motorcycle, space available to locate the clutch is small and clutch is enclosed in a cover.
2. With multiple plates, surface strength and friction in engaged clutch are increased.
3. Depending upon the power output of the engine and weight of two wheeler, 4 to 8 sets of
plates are required and assemble in single cover.
4. The clutch plates and friction plates are immersed in oil bath, hence known as wet clutch and
operate smoothly.
5. Oil helps the clutch to run cool. Debris resulting from clutch wear can be drain easily with oil. 6.
This type of clutch has more life and depends upon the quality of oil used.

10. State function of clutch. Describe Centrifugal Clutch used in LMV with neat sketch
(W-16) (W-17)
ANSWER :
i) Clutch disengages and engages the engine to the transmission whenever required.
ii) It transmits engine power to the gear box.
iii) By using clutch we are able to shift the gears smoothly without damaging gear teeth.

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OR

The centrifugal clutches are usually incorporated into the motor pulleys. It consists
of a number of shoes on the inside of a rim of the pulley, as shown in fig. The outer surface of
the shoes are covered with a friction material. These shoes, which can move radially in
guides, are held against the boss (or spider) on the driving shaft by means of springs. The
springs exert a radially inward force which is assumed constant. The mass of
the shoe, when revolving, causes it to exert a radially outward force (i.e. centrifugal force).
The magnitude of this centrifugal force depends upon the speed at which the shoe is
revolving. A little consideration will show that when the centrifugal force is less than the
spring force, the shoe remain in the same position as when the driving shaft was
stationary, but when the centrifugal force is equal to the spring force, the shoe is just
floating. When the centrifugal force exceeds the spring force, the shoe moves outward and
cones into contact with the driven member and presses against it. The force with which the
shoe presses against the driven member is the difference of the centrifugal force and the
spring force. The increase of speed causes the shoe to press harder and enables more
torque to be transmitted.

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11. Describe construction and working of vario- drive used in mopeds. (W-14)(W-16)
ANS :

Construction: Vario- drive consists three basic components- A high power metal or rubber belt, A
variable input driving pulley which is connected to the crankshaft of the engine, output driven
pulley which transfers energy to the drive shaft. Each pulley is made of two 20 degree cones facing
each other. A belt rides in the groove between the two cones. This assembly has rollers which
move in and out depending on the load condition and engine rpm giving the differential pulley
diameter thus providing the optimum wheel rpm and traction force V belts are preferred if the belt
is made of rubber.

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Working: When the two cones of the pulley are far apart (When the diameter increases) the belt
rides lower in the groove and the radius of the belt loop going around the pulley gets smaller.
When the cones are close together (when the diameter decreases), the belt rides higher in the
groove and the radius of the belt loop going around the pulley gets larger. CVTs may use hydraulic
pressure, centrifugal force or spring tension to create the force necessary to adjust the pulley
halves.

12. Describe working of constant mesh gearbox.

(S-15) (W-15) (S-16)(W-16)(S-17)(W-17)(S-18)
ANS :

Construction: A simplified diagram of constant mesh box has been shown in Figure. In this gear
box, all gears on the main transmission shaft are constantly connected to corresponding gears on
countershaft or lay shaft. In addition, two dog clutches are provided on the main shaft. One dog
clutch is between the third gear and clutch gear and another is between the first (Low) gear and
second gear.
Working: Top or 4th speed gear is obtained when the left dog clutch is slides to left to mesh with
clutch gear by using the gear shift lever. In this case, main shaft rotates at the same speed as that of
clutch gear or engine crankshaft speed which is the maximum speed. Third gear is obtained when
dog cutch (left side) meshes with third gear on main shaft. In this way by sliding the second dog
clutch, second and first gears are obtained.

13. What is gear ratio? Write the gear ratios for motorcycle. (W-15) (W-17)
ANS :
Gear ratio: Gear ratio is ratio of number of teeth on the driven gear to number of teeth on the
driving gear. In a motorcycle there are more than one gear at work so there also are more gear
ratio. All these are working together and form the overall ratio. Most gearing consists of:
1. Primary drive, this is the gear ratio between engine RPM and the clutch shaft RPM, also called
'Primary reduction ratio'
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2. Gearbox ratio, this is the ratio between the clutch shaft RPM and the countershaft RPM. Because
there are more gears in a gearbox, different ratio are possible
3. Final drive ratio, this is the ratio between countershaft RPM and rear sprocket RPM.
In the low gear the driven gear almost has more teeth and in the higher gear, the driven gear has
less number of teeth compare to the driving gear.
Gear ratio for motorcycle (YamahaYZF-R15):

Primary reduction ratio 73/24(3.042)

Secondary reduction ratio 42/14(3.000)
Gear Ratio
1 st 34/12(2.833:1)
2 nd 30/16(1.875:1)
3 rd 30/22(1.1364:1)
4 th 24/21(1.143:1)
5 th 22/23(0.957:1)
6 th 21/25(0.840:1)

14. Compare two wheeler gear box with four wheeler gear box.
(W-14) (S-15) (W-15)(S-17)(W-17)

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15. Compare chain drive with belt drive (S-16)(W-17)

ANSWER :
Sr. Chain drive Belt drive
1. They have reduced noise emission They are quieter in operation. Noisy
operation during initial acceleration.
2. Most efficient system Comparable with chain drive
3. Smallest width Wider than chain drive.
4. Proper and periodic lubrication is No lubrication for belt. Belts do not rust
necessary.
5. You can split a chain and replace it Belt replacement requires removal of
easily. swing arm.
6. Cost lowest Cost moderate
7. Max Velocity Ratio is maintained Less Velocity Ratio is maintained
8. Application-Motorcycle Application- Scooterate, mopeds

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