Supercharged KTM Engine for Snowmobile

The goal of the project is to design and manufacture a supercharged single-cylinder four-stroke engine that would package in a snowmobile chassis.

=Problem Definition=

In this project, we will be supercharging a KTM 540 SXS motorcycle engine with an Eaton Supercharger and redesigning it to fit inside a snowmobile chassis to achieve better fuel efficiency, more power, and weight reduction.



Background
The University of Idaho Clean Snowmobile Challenge (CSC) Team reengineers snowmobiles to improve emissions, noise, and fuel economy. CSC is a SAE International Collegiate Design Series interdisciplinary competition that the University have been competing for sixteen years. The competition is held annually in Houghton, Michigan. The U of I team has won the competition in 2002, 2003, 2007, and has acquired more than 50 awards. U of I's team is the only team in CSC history to win the aspired Founder's Trophy award back-to-back in 2015 and 2016.

Previous senior design project, seniors designed and manufactured a robust platform for testing and optimization for the next generation formula SAE vehicle utilizing the KTM engine.

Deliverables

 * Assemble a KTM 540 SXS motorcycle engine
 * Construct CAD models of the layout of the engine, crankcase, crankshaft, connecting rod, camshaft regrind, camshaft chain drive, oil and water pumps, and mounts for the superchargers
 * Gather measurements with the 3D Scanner, calipers, and measuring tape
 * Determine compression ratio, horse power, air to fuel ratio, and fuel efficiency
 * Prototype of the design
 * Record of cost and materials
 * Final report of how to design and manufacture this supercharged engine for a snowmobile

Specifications


=Project Learning=

The KTM engine was given to the team disassembled with a box full of parts. While re-assembling the engine back together, we gain more knowledge of how it worked, how we were going to design the new crankcase, and how to attach the supercharger on it. Also, we found parts that we needed and didn't need.



Right casing half of the engine.



Left and right casings attached together.



Crankshaft, camshaft, piston, and cylinder head installed.



Flywheel and oil pump installed.

The KTM engine is missing some gears, transmission, and starter. The engine will need new spark plugs, oil, and gaskets.

=Project Plan= Running the Supercharger:
 * We will running the supercharger with a belt that is driven by the crankshaft.
 * We will figure out the optimal running RPM for the supercharger and get a pulley that achieves that RPM.
 * The supercharger will be mounted in an orientation that the pulley lines up with the crankshaft.
 * We will design a system for an air bypass so the supercharger does not have to run at lower RPMs.

Crank Case Creation:
 * The stock transmission is not included and not needed so the whole crankcase needs to be designed and manufactured.
 * We will create a smaller custom fabricated crank case that has few components.

Engine Modifications:
 * We will change the compression ratio lower than 11.5:1.
 * There is a possibility of it being around 9:1 to allow for running higher boost from the supercharger.
 * We will use an electric starter instead of the kick starter.

=Final Design=

=Validation=

=Team Members=

=Additional Documentation= Project Schedule

Product Requirements

Bill of Materials

Budget

KTM Manual

Meeting Minutes

Presentations