PT.

BAJAJ AUTO INDONESIA, PRESENTS

BAJAJ
Technical Aspect
 TECHNICAL ASPECT

• Frame Components
• Vehicle Terminologies
• Engine Components
• Engine Terminologies
• Emerging Technologies
 FRAME COMPONENTS
The skeleton of our body keeps it straight and all organs in
place.

Similarly, the
skeleton of
the vehicle
keeps it
straight and
all parts in
place.

It is called the FRAME.


MONOCOQUE TYPE FRAME
Monocoque Type frame is
generally made of Sheet
Metal and is a one-piece unit.
Monocoque Type is used in
Bajaj Chetak, Legend and M-
80.
FRAME TYPE
SEMI DOUBLE CRADLE FRAME
The motorcycle frames, which
are made of steel tubes, are
classified as double cradle and
semi double cradle type. Semi
Double Cradle frame has a single
tube starting from steering tube
and then divides into two tubes to
form a cradle on which engine is
mounted. Semi Double Cradle
frame is used on Bajaj Caliber
and Boxer motorcycles.
DOUBLE CRADLE FRAME
Double cradle frame has two
tubes emerging from the
steering tube towards
engine to form a cradle on
which the engine is
mounted. Double Cradle
frame is used on Bajaj
Eliminator, Pulsar and KB
100 RTZ motorcycles.
 FRAME COMPONENTS

Nitrox Rear Shock Absorber

Front Shock Absorber

 FRAME COMPONENTS

NITROX REAR SHOCK ABSORBER

Front Shock Absorber

Front Shock Absorber is a
media, which connects the
front wheel to the frame and
has provision for mounting the
handle bar. When the front
wheel goes on ditches and
potholes or speed breakers, it
absorbs shocks. This avoids Kompresi Ekspansi
shocks to the rider.
 FRAME COMPONENTS
CONSOLE PANEL
It is a cluster of meters mounted at the
front on the handle bar. Performance
indicative devices like speedometer,
tachometer, fuel meter, pilot indicator
light, etc. are clubbed in this cluster.
BATTERY
Battery is basically an energy
storage device. Energy is stored in
the form of reactive chemicals. This
stored chemical energy is converted
into electrical energy when required,
and supplied to various appliances
on the vehicle like light, horn and for
self-starting.
 VEHICLE TERMINOLOGIES

Our body is associated with various terms like tall, short, dwarf, fat
so is the vehicle associated with various terms and terminologies.
 VEHICLE TERMINOLOGIES

HEIGHT OF THE VEHICLE SADDLE HEIGHT

Height of the vehicle is the Saddle height, is the distance

distance between the ground
and the highest portion of the
vehicle, when both the tyres
are in contact with the ground
and are inflated to correct tyre
pressure.
between the ground and the rider
seat top where the rider sits, when
both the tyres are in contact with the
ground and are inflated to correct
tyre pressure.
 VEHICLE TERMINOLOGIES

LENGTH OF THE VEHICLE WIDTH OF THE VEHICLE

Width of the vehicle is the

Length of the vehicle is the maximum width including
distance between front end and protrusion of any standard
the back end of the vehicle with all fitments on the vehicle.
standard fitments.
 VEHICLE TERMINOLOGIES
WHEELBASE
Wheel Base is the distance
between the centre of front axle
and the centre of rear axle when
both the wheels are in the same
plane. Wheel Base plays an
important role in the stability of
the vehicle.
GROUND CLEARANCE
Ground Clearance is the distance
between any lowest part of the
vehicle and the ground, when both
the tyres are in contact with the
plane ground and are inflated to
correct tyre pressure. If the ground
clearance is not adequate the
vehicle base is bound to hit speed-
breakers or bumps. Also, the
ground clearance needs to be
optimum and not very high.
 VEHICLE TERMINOLOGIES

TURNING CIRCLE RADIUS

Turning Circle Radius is the
radius of a circle drawn by the
front wheel on turning when
the handle bar is turned to
fullest turning position on
either side.
 ENGINE COMPONENTS

Heart pumps energy into the body.

Engine generates power for working of the vehicle.
It converts chemical energy of petrol into mechanical energy for motion
of the vehicle.
 ENGINE COMPONENTS
SPARK PLUG
Spark plug is fitted in the cylinder head
and is a part of ignition system. It receives
high voltage current from H.T. Coil and
creates spark in the combustion chamber
that ignites the air fuel mixture in the
cylinder. This generates power for piston
movement.
CYLINDER HEAD
Cylinder head encloses the top of the
cylinder block. It contains combustion
chamber cavity in which the burning of air
fuel mixture takes place.
In four stroke engine it houses spark plug,
combustion chamber, inlet and exhaust
valves, valve passage openings, camshaft,
rocker arms, rocker shafts, etc. Whereas, in
two stroke engine, the cylinder head contains
combustion chamber and spark plug only.
 ENGINE COMPONENTS
CYLINDER BLOCK
Cylinder block is fitted above the
crankcase. It has fins for air-cooling
process.
Cylinder block of four stroke engine is a
plain cylindrical bore which guides the up
and down movement of the piston. It has
a provision to accommodate cam chain
and chain tensioner.
In case of two-stroke engine the cylinder
block has transfer ports and exhaust
ports.
VALVES
There are at least two valves per cylinder.
One is Inlet valve and the other is Exhaust
valve. Inlet valve head size is larger than
exhaust valve.
Valves are used to open and close the inlet
and exhaust passage in the cylinder head,
which leads to combustion chamber. Inlet
valve allows intake of fresh air and exhaust
valve allows exhaust of burnt gases.
 ENGINE COMPONENTS

CAMSHAFT & ROCKER ARMS PISTON

Piston is a cylindrical metal block, which
Camshaft and rocker arm are used to
moves up and down in the cylinder block.
operate the valves.
It receives the power from exploded gasses
The camshaft is connected to the
and transmits it to the crankshaft through
Crankshaft with the help of sprockets
connecting rod. Piston has piston rings to
and cam chain.
maintain pressure tight seal between moving
piston and cylinder to maintain compression
pressure.
 ENGINE COMPONENTS
CRANK SHAFT
Crankshaft consists of connecting rod
and webs. The top-end of the
connecting rod is connected to the
piston by piston-pin, and the bottom-end
is connected to the crankshaft webs with
crankpin.
Connecting rod and crankshaft together
convert the up and down motion of the
piston into rotary motion of the
crankshaft.
CLUTCH
Clutch is a device used to engage and disengage
power from the crankshaft to the gear transmission
at riders will.
It consists of clutch box, clutch wheel, clutch hubs,
friction plates and steel plates.
Partial clutch operation gives less power to the
wheels leading to higher fuel consumption
 ENGINE COMPONENTS

GEAR TRANSMISSION CRANKCASE

Gear transmission consists of Input shaft, Crankcase is the main body of the engine,
Output shaft, Speed gears, etc. which houses crankshaft, clutch, gear
Gear transmission alters the engine torque transmission, etc. and also acts as a sump
and transmits it to the rear wheel for engine oil. Cylinder block is mounted on
- To increase pulling power and the crankcase.
- To increase the speed of the vehicle
Input shaft receives power from the clutch and
output shaft supplies the power to rear wheel
through sprocket and chain.
 ENGINE COMPONENTS

CARBURETTOR MAGNETO ASSEMBLY

Carburetor is a device, which breaks the Magneto assembly is a device, which

petrol into minute particles and mixes air generates electricity to meet various
and petrol in correct proportion to meet the requirements like lighting, horn etc.
engine requirement at various speed and It consists of stator plate with copper wound
load of the engine. coils and a magnetic rotor.
 ENGINE TERMINOLOGIES

Heart-beat, palpitation are terms associated with the working of our heart.
Stroke, horse power, ignition are terms associated with the working of an engine.
 ENGINE TERMINOLOGIES

TOP DEAD CENTRE (TDC) BOTTOM DEAD CENTRE (BDC)

TDC stands for Top Dead Centre. The
piston moves up and down inside the
cylinder. TDC is the position of the
piston top when it has traveled to top
most position.
BDC stands for Bottom Dead Centre. It is
the position of the piston top, when it has
reached the bottom most position.
 ENGINE TERMINOLOGIES

BORE STROKE

Bore is the inside diameter of the Cylinder
Block in which the Piston moves up and
down.
It is the distance traveled by the piston
from top to bottom or bottom to top.
Strokes are required to complete the
four basic processes of the engine viz.
Suction, Compression, Power and
Exhaust.
 ENGINE TERMINOLOGIES
CUBIC CAPACITY / DISPLACEMENT
It is the volume generated by the piston
when it moves from top end to bottom end.
It is measured in Cubic Centimeter (CC). It
is also called as Displacement volume.
Engines are always specified, according to
their cubic capacities. Like 100 cc, 110cc
etc.
COMPRESSION RATIO
It is the ratio between Total Volume in the
engine to the Clearance Volume available at
the end of the compression stroke.
For example, if the total volume drawn in
during suction is 100 cc and if it is compressed
to 10cc at the end of compression stroke, then
the compression ratio is specified as 100:10 or
10:1
 ENGINE TERMINOLOGIES
BRAKE HORSE POWER
BHP stands for Brake Horse Power.
Brake Horse Power is the actual power
available to the crankshaft after deducting the
frictional losses. Therefore, Indicated Horse
Power minus Frictional Horse Power is equal
to the Brake Horse Power.
IGNITION TIMING
Ignition timing is the timing at which spark
occurs in the combustion chamber just
before piston reaches TDC position, during
compression process for complete
combustion of the charge.
If spark occurs earlier than specified ignition
timing, it is called ‘Advance’ timing.
If spark occurs after the specified ignition
timing, it is called ‘Retard’ timing.
 ENGINE TERMINOLOGIES

IDLING SPEED FINAL DRIVE RATIO

It is the speed of the crankshaft i.e. rpm of the
engine when the throttle is in closed position. At
this time crankshaft must rotate uniformly.
Higher Idling Speed:
- Higher vibration on stationery vehicle
- Higher fuel consumption
It is the relative rotation between engine
sprocket and a sprocket on rear wheel. Both
the sprockets are connected through drive
chain.
For example: if the engine sprocket has 10
teeth and rear wheel sprocket has 50 teeth,
then the final drive ratio is said to be 5:1.
 WORKING PRINCIPLES

Contraction and relaxation of the heart transmits energy into our body.
Suction, Compression, Power & Exhaust of the engine generates energy for the vehicle.
 WORKING PRINCIPLES

The working of a 4 Stroke Engine

In a 4 Stroke engine the Inlet Valve &

Exhaust valve are mounted in the cylinder
head. Inlet valve controls the entry of fresh
air fuel mixture inside the cylinder and the
Exhaust valve allows burnt gases to escape
from the cylinder.
SUCTION STROKE

During the suction stroke the piston moves from TDC to

BDC.
The exhaust valve is in closed position while the inlet
valve remains open.
Due to the piston movement suction occurs i.e. a
vacuum is created inside the cylinder.
So, the air fuel mixture enters into the cylinder through
inlet valve, till the piston reaches BDC. This completes
the suction stroke.
 WORKING PRINCIPLES
COMPRESSION STROKE
- After suction stroke, the piston moves from BDC
to TDC.
- During this time, both the inlet and exhaust valve
remain closed.
- The air fuel mixture inside the cylinder gets
compressed.
- This increases the temperature of the mixture,
which helps for complete combustion.
- Just before the end of the compression stroke, a
spark is introduced at the spark plug.
POWER STROKE
- Due to the occurrence of the spark the
compressed air fuel mixture gets ignited
and explodes. Thus, piston moves from
TDC to BDC.
- During this time both the inlet and
exhaust valve remain closed.
- This completes the power stroke.
WORKING PRINCIPLES

During the exhaust stroke the piston moves from BDC to

TDC.
At this time the exhaust valve remains open while the inlet
valve is in closed position.
The piston pushes the burnt gases.
The burnt gases expel out through the exhaust valve in the
cylinder head. This completes the exhaust stroke.
Again piston starts moving from TDC to BDC to start the
suction process, which is followed by compression, power
and exhaust. In this way 4S engine executes all the four
strokes of the engine in 4 strokes of the piston or 2 rotations
of the crankshaft.
 WORKING PRINCIPLES

4 STROKE ENGINE 2 STROKE ENGINE

 Cont’d
4 STROKE ENGINE
The cycle is completed in four strokes of
the piston or in two revolutions of the
crankshaft. Thus one power stroke is
obtained in every two revolutions of the
crankshaft (in case of single cylinder).
Because of one power stroke for two
revolutions, power produced for same size
of engine is less or for the same power the
engine is heavy and bulky.
Because of one power stroke in two
revolutions lesser cooling and lubrication
requirements. Lesser rate of wear and
tear of cylinder block.
2 STROKE ENGINE
The cycle is completed in two strokes of
the piston or in one revolution of the
crankshaft. Thus one power stroke is
obtained in each revolution of the
crankshaft.
Because of one power stroke for one
revolution, power produced for same
size of engine is more (theoretically
twice, actually about 1.3 times), or for
the same power the engine is light and
compact.
Because of one power stroke in one
revolution greater cooling and lubrication
requirement. Greater rate of wear and tear
of cylinder and piston.
 Cont’d

4 STROKE ENGINE 2 STROKE ENGINE

The four stroke engine contains valves and Two stroke engine have no valves but only
valve mechanism. ports.

Because of the heavy weight and Because of lightweight and simplicity due
complication of valve mechanism, higher in to the absence of valve mechanism,
initial cost. cheaper in initial cost.

Volumetric efficiency high due to more time Volumetric efficiency less due to lesser time
for induction for fresh air fuel mixture. for induction of fresh air fuel mixture.

Thermal efficiency higher. Thermal efficiency is lower. In two stroke

petrol engine some fuel is exhausted during
scavenging.

Weight to power ratio more. Weight to power ratio less.

 EMERGING TECHNOLOGIES

Advancements in Medical Science has given us various options to face odds.

Emerging Technologies has made our vehicles safe, environment friendly and better controlled.
 EMERGING TECHNOLOGIES
CATALYTIC CONVERTER
The catalytic converter converts hazardous gases
into harmless gases.
The construction of the catalytic converter is slightly
different in scooters and motorcycles, although their
working principle is same.
- The catalytic converter for scooter consists of a
container and a substrate.
- The substrate is a honeycomb like structure with
hundreds of parallel channels. Substrate is coated
by wash coat and catalyst.
- The density of channels for 2 wheelers is 100 cells
per square inch.
The catalytic converter for motorcycles consists of only container coated with Wash Coat and
Catalyst.
- Wash coat means intermediate layers of alumina, which are suitable for adhering to catalyst.
- Catalyst is a coating of noble metals like platinum, rhodium, and palladium.
The catalytic converter is located on the engine side near the exhaust. When exhaust gases pass
through the catalytic converter, chemical action takes place between exhaust gases and noble
metals, resulting in conversion of hazardous gases into harmless gases.
- Carbon monoxide gets converted to carbon dioxide.
- Hydrocarbons get converted to carbon dioxide and water vapor.
- Nitrogen oxide gets converted to Nitrogen.
 EMERGING TECHNOLOGIES
SECONDARY AIR INDUCTION SYSTEM
Secondary Air Induction System dilutes the
carbon monoxide coming out from the exhaust
gases to reduce pollution.
It consists of reed valve and vacuum switch. The
vacuum switch consists of diaphragms. The
vacuum switch is connected to the air filter
whereas the reed valve is connected to the
exhaust valve passage in the cylinder.
When the exhaust gases rush with high velocity
into the exhaust passage, low pressure is created
in the passage and the reed valve opens. Fresh
and filtered air from the air filter is induced into the
exhaust passage. The oxygen in the fresh air
enables the carbon monoxide present in the
exhaust gases to oxidize and form carbon dioxide,
thus reducing the carbon monoxide level in the
gases flowing through the silencer.
 Cont’d
SECONDARY AIR INDUCTION SYSTEM
On sudden de-acceleration, the air fuel mixture will be rich in fuel as compared to air. This high
petrol mixture will be discarded through the exhaust during the exhaust stroke. The high petrol
content mixture will react with the oxygen in the fresh air creating an explosion in the silencer. This
after fire effect in the silencer is avoided by the introduction of a small tube in the vacuum switch,
which is connected to the inlet manifold of the engine.
When sudden de-acceleration takes place, the vacuum in the inlet manifold increase, due to which
the diaphragm in the vacuum switch is pulled against the spring tension. This restricts the air supply
to the reed valve. Once, the vacuum stabilizes the diaphragm opens due to spring tension and air
starts flowing.
Due to Secondary Air Induction System, the vehicle becomes environment friendly and fulfills the
stringent emission norms due to very less emission of carbon monoxide.
 EMERGING TECHNOLOGIES
POSITIVE CRANK CASE VENTILATION

Positive crank case ventilation consists of breather tube, which is connected to air filter case and a
container attached to air filter. The temperature inside the engine causes the engine oil to
evaporate. These hot fumes from the crankcase flow to the air filter assembly through the breather
tube.
Due to the temperature difference, hot fumes get condensed in the air filter and become oil
droplets. These oil drops are collected in a container thus it prevents exposure of hazardous fumes
into the atmosphere. Thereby, making the vehicle environment friendly.
 EMERGING TECHNOLOGIES

ANTIDIVE FRONT SUSPENSION

Antidive front suspension restricts diving tendency of the rider while riding, on the application of the
front brake. Antidive Front Suspension consist of front shock absorber, cushion arm, cushion arm
pivot and torque link. In normal driving, shock absorber with spring absorbs shocks and cushion arm
swings on pivot shaft. On applying braking, brake shoe gets locked with the drum. Hence, brake
panel tends to twist. Twisting of panel is restricted by the torque link. Torque link transfers the
twisting force to the steering column.
Thus Antidive front suspension restricts the diving tendency of rider on applying front brake. It also
transfers less vibration to the riders’ body and ensures more comfortable ride.
Antidive front suspension is available on Bajaj scooters.
 EMERGING TECHNOLOGIES
TELESCOPIC FRONT SUSPENSION

Telescopic front suspension is normally fitted on

motorcycles, and is also popularly known as Ceriani
type front suspension. Now days it’s fitted on
scooters also.
Telescopic front suspension consists of outer tube,
inner tube, main spring, cylinder and oil.

Whenever the front wheel receives shocks, the inner tube moves downward in the outer tube. Due
to the presence of oil and spring, the movement of the tubes is slowed down which dampens the
shocks.
During the extension stroke, the compressed main spring extends to push the inner tube to its
original position. Again the shocks are dampened because of the presence of oil. The holes and
valves in the cylinder guide the flow of oil. In this way telescopic front suspension gives a smoother
ride.
 EMERGING TECHNOLOGIES
AUTOMATIC FUEL COCK FOR SAFFIRE
Automatic fuel cock of Saffire consists of Inlet
connected to petrol tank, Outlet connected to
carburettor, Vacuum tube connected to inlet manifold
of the engine, diaphragm and spring. Automatic fuel
cock supplies petrol to the carburettor only when
engine is running and stops the supply when engine
is stopped.

Petrol from petrol tank is fed to fuel cock by gravity. On starting the engine due to piston movement
vacuum in created in the inlet manifold. This vacuum pulls the diaphragm and inlet opens. Thus,
petrol flows into the cock and further to the carburettor. On stopping the engine, due to the absence of
vacuum the diaphragm comes back to its original position and petrol supply stops.
Automatic fuel cock is convenient as ON / OFF takes place automatically.
 EMERGING TECHNOLOGIES
AUTOMATIC FUEL COCK FOR ELIMINATOR
The automatic fuel cock for Eliminator is different from
Saffire fuel cock. It is also vacuum operated with reserve
facility. In ON and RESERVE position the petrol cock
supplies the petrol automatically.
It consists of Diaphragm, Control valve, Vacuum pipe
connected to inlet manifold and Outlet pipe connected to
carburettor. Pipe for ON supply and pipe for RESERVE
supply are connected to petrol tank. When fuel cock is in
ON position, petrol is supplied through the ON pipe to
the fuel cock by gravity. Petrol will not flow further as
diaphragm blocks the passage. When the engine is
started, the vacuum created in the vacuum pipe pulls the
diaphragm and opens the passage for the petrol to flow
to the outlet pipe.
When petrol level goes down to reserve level, the petrol supply stops. On shifting to reserve position
petrol starts flowing again through reserve pipe and due to vacuum and the diaphragm movement
petrol starts flowing through the outlet. Apart from On and Reserve position the fuel cock has got
“PRIME” position for supply of petrol. Sometimes while shifting form ON to RESERVE there are
chances of air getting locked in fuel pipe.To overcome the air lock, the petrol cock needs to be kept
in prime position for a moment due to which the petrol flows directly from reserve pipe to outlet
pipe.During this position the vacuum operated system is by-passed. Once the engine starts in Prime
position fuel cock should be shifted to Reserve position.
 EMERGING TECHNOLOGIES
AUTOMATIC CAM CHAIN TENSIONER

Automatic Cam Chain Tensioner maintains

the cam chain tension constantly and
effectively. It consists of Body, which tapers
inside, Push Rod, Ball Retainer and Spring.

Pushrod is always in contact with the chain guide. The cam chain tends to get loose due to wear. To
maintain the tension push rod always pushes the chain forward. The forward movement of the push
rod is achieved due to the taperness in the body. Push rod cannot move backward inside the body
as the balls on the retainer clamp the rod.
It is simple in mechanism with less working components, has positive action and almost no
maintenance.
 EMERGING TECHNOLOGIES
DUAL OIL FILTER LUBRICATION SYSTEM

This is double oil filter lubrication system. This is

present in caliber and eliminator motorcycles. It
consists of primary filter, oil pump and paper
element oil filter.
In the engine the oil sucked by the oil pump is
primarily filtered by Primary Filter. Then, the
pressurized oil coming from the oil pump gets
filtered by the paper element oil filter.

The Paper Element Oil Filter filters the oil to micro level. Finally, oil is then supplied to various
engine components for lubrication. In this way dual oil filter system ensures clean oil supply for
lubrication of critical engine components and longer life of components.
 EMERGING TECHNOLOGIES
DISK BRAKE

While riding for better control and effective stopping, simultaneous application
of front and rear brake is essential. In case of drum brakes on front wheel, the
force applied by hand is not sufficient. Hence, disc brakes are incorporated on
front wheel because it requires very less force for operation. As the braking
force for rear wheel is supplied by foot, the force applied is sufficient and disc
brakes are not required. On the other hand, if disc brakes were provided on
rear wheel, it would increase the skidding tendency on its wrong application.
However the disc brake on the rear wheel is used only for high powered, high
speed vehicles.The disc brake system consists of master cylinder, hose pipe,
caliper assembly, brake pads and disc. The master cylinder converts the force
exerted by the rider on the brake lever into hydraulic pressure. This force is
transmitted to the caliper assembly, through hose pipe for generating braking
torque. In the caliper assembly due to hydraulic pressure the brake pads are
pushed forward to grip the disc thereby stopping the vehicle. On releasing the
front brake lever the brake pads move back to their original position.

Disc brakes have certain advantages over drum brakes:

- Disc brake has better heat dissipation capacity as it is open to air and has holes on the disc.
- Mud and water cannot accommodate on the disc, as it will be scraped away through holes.
- Disc brakes are more effective.
- It requires less maintenance except the oil level in the master cylinder needs to be topped up.