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.



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
Stock KTM 540 SXS Engine Specifications Supercharged KTM 540 SXS Engine Specifications
 * Ratio: 11.5:1
 * Around 80 hp

Stock engine vs Supercharged engine comparison to the right.

=Design Considerations= Running the Supercharger:
 * We will be looking into running the supercharger from a belt that is driven off the crankshaft.
 * We will have to figure out the optimal running RPM for the supercharger and get a pulley that achieves that RPM.
 * The SC will have to be mounted in an orientation that the pulley lines up with the crankshaft.
 * We will design a system for an air bypass so the SC does not have to run at all engine RPM.

Crank Case creation:
 * There will not be a need for the stock transmission gears and so the whole crankcase on that end is unnecessary.
 * We will create a smaller and most likely custom fabricated crank case that only has a few components.

Engine Modifications:
 * We will look into changing the compression ratio to something lower than 11.5:1.
 * There is a possibility of it being around 9:1 to allow for running higher boost from the Supercharger.

=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.

=Final Design=

=Validation=

=Team Members=

=Additional Documentation= Project Schedule

Product Requirements

Bill of Materials

Budget

KTM Manual

Meeting Minutes

Presentations