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Electronic Fuel Injection System for a 2-Stroke All-Terrain Vehicle

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Electronic Fuel Injection System for a 2-Stroke All-Terrain Vehicle Electronic Fuel Injection System for a 2-Stroke All-Terrain Vehicle A Baccalaureate thesis submitted to the School of Dynamic Systems College of Engineering and Applied Science University of Cincinnati in partial fulfillment of the requirements for the degree of Bachelor of Science in Mechanical Engineering Technology by Nick Strickland April 2013 Thesis Advisor: Ahmed Elgafy, PhD ACKNOWLEDGEMENTS I would like to thank all the help that Angus Kennedy for Kennedy Powersports gave me and allowing me to use his dyno and garage for testing. I would like to thank Anthony Evers for making the manifold and flywheel. I would like to thank RC Engineering for donating the injectors. I would like to thank Gary of GT Stators for making a custom stator for this project. ii TABLE OF CONTENTS ACKNOWLEDGEMENTS ...................................................................................................... II LIST OF FIGURES ................................................................................................................ IV LIST OF TABLES .................................................................................................................. IV ABSTRACT ............................................................................................................................ VI INTRODUCTION .................................................................................................................... 1 BACKGROUND .................................................................................................................................................... 1 CURRENT CARBURETOR SYSTEMS ................................................................................. 2 STOCK CARBURETOR.......................................................................................................................................... 2 AFTERMARKET CARBURETORS ........................................................................................................................... 3 Mikuni Carburetors ...................................................................................................................................... 3 Keihin Carburetors ....................................................................................................................................... 3 Lectron Carburetors ..................................................................................................................................... 5 EFI CONVERSION FOR AUTOMOBILES ........................................................................... 5 CUSTOMER FEEDBACK, FEATURES, AND OBJECTIVES ............................................. 7 SURVEY ANALYSIS ............................................................................................................................................. 7 PRODUCT FEATURES AND OBJECTIVES ............................................................................................................... 8 ANALYSIS FOR ENGINEERING CHARACTERISTICS .................................................. 10 SCHEDULE ............................................................................................................................ 12 BUDGET ................................................................................................................................ 12 DESIGN .................................................................................................................................. 12 DESIGN CONCEPTS ........................................................................................................................................... 13 Twin Throttle Bodies ................................................................................................................................... 13 Single Throttle Body TBI ............................................................................................................................ 13 Single Throttle Body Port Injection ............................................................................................................ 14 Design Selection.......................................................................................................................................... 15 CALCULATIONS ................................................................................................................................................ 15 Fuel Injector Size ........................................................................................................................................ 15 Throttle Body Size ....................................................................................................................................... 16 Fuel Pump Size ........................................................................................................................................... 16 DESIGN DRAWINGS .......................................................................................................................................... 16 ‘Y’ Manifold ................................................................................................................................................ 16 Coolant Temp Sensor Mount....................................................................................................................... 18 Air Filter Adapter ....................................................................................................................................... 19 COMPONENT SELECTION .................................................................................................................................. 20 Throttle Body .............................................................................................................................................. 20 Injectors ...................................................................................................................................................... 21 Engine Control Unit .................................................................................................................................... 22 Sensors ........................................................................................................................................................ 22 TESTING ................................................................................................................................ 23 CARBURETOR TESTING ................................................................................................................................ 23 EFI TESTING ..................................................................................................................................................... 24 RESULTS ............................................................................................................................... 25 iii WORKS CITED ..................................................................................................................... 26 APPENDIX A – PRODUCT RESEARCH .............................................................................. 1 APPENDIX B – SURVEY RESULTS ..................................................................................... 1 APPENDIX C – QFD ............................................................................................................... 1 APPENDIX D – PRODUCT OBJECTIVES ............................................................................ 1 APPENDIX E – SCHEDULE .................................................................................................. 1 APPENDIX F – BUDGET ....................................................................................................... 1 APPENDIX G – PE-ECU-3 ..................................................................................................... 1 LIST OF FIGURES Figure 1 - Yamaha Banshee Stock Carburetors ........................................................................ 2 Figure 2 – Mikuni VM Round Slide Carburetors (3) ............................................................... 3 Figure 3 – Mikuni TM Series Carburetor (3)............................................................................ 3 Figure 4 – Keihin PJ Carburetor (5) ......................................................................................... 4 Figure 5 – Wicked Motorsports 34mm PJ intake system (4) .................................................... 4 Figure 6 - Keihin PWK Carburetor (5) ..................................................................................... 4 Figure 7 – Trinity Racing Constant Velocity System (6) ......................................................... 5 Figure 8 - Lectron Carburetor (7) ............................................................................................. 5 Figure 9 - Chevrolet 262-400 V8 EFI Kit (10) ......................................................................... 6 Figure 10 - Stock Carburetor vs. EFI system (10) .................................................................... 6 Figure 11 - FAST EZ EFI Kit (11) ........................................................................................... 7 Figure 12 – Dual Throttle Bodies sketch ................................................................................ 13 Figure 13 – Single Throttle Body TBI sketch ......................................................................... 14 Figure 14 – Single Throttle Body Port Injection sketch ........................................................
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