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HMV2R Haynes Build Your Own
V-Twin Motorcycle Engine Kit

© Haynes Publishing 2015

All rights reserved. No part of this

publication may be reproduced, stored in a
retrieval system or transmitted, in any form
or by any means, electronic, mechanical,
photocopying, recording or otherwise,
without prior permission in writing from
the publisher.

First published in 2014

Published by Haynes Publishing

Printed in China

Please retain the information in

this manual for future reference.
BUILD YOUR OWN
V-TWIN MOTORCYCLE
ENGINE
Contents
Introduction ................................................................................................... 2
Notes and advice ........................................................................................... 5
Parts list ......................................................................................................... 6
Assembling the engine .................................................................................. 12
How an engine works .................................................................................... 29
Basic engine terms ........................................................................................ 32
 INTRODUCTION INTRODUCTION

There are many different shapes and sizes of internal combustion engine, from small The valves on engines tend to be operated by pushrods, or by chain-driven or gear-driven
single-cylinder model aircraft engines, right up to the large multi-cylinder engines used in overhead camshafts, each design having its own advantages and disadvantages. Pushrod
industrial machinery and ships. Motorcycles have been around since the late 1880s, and their engines are simpler – a camshaft is mounted in the engine block, and a series of rods transfer
engines have steadily evolved to suit a wide range of uses, including day-to-day commuting, the up/down profile of the cam to the valves via rockers. An overhead camshaft (OHC) design
long distance touring and racing. This kit is designed to represent a type of engine commonly has the camshaft mounted in the cylinder head, which operates the valves directly or via
used in motorcycles (‘bikes’), so it’s this configuration we'll concentrate on. rockers. The greater number of moving parts in the pushrod valve mechanism means that it
cannot operate as fast as the OHC design, so is more suited to lower performance engines.
Production motorcycle engine designs have included single, twin, triple, four and six-cylinder The OHC valve arrangement is lighter and can operate at much higher speeds, though the
layouts, the most common being the four cylinder arrangement. As a general rule, the mechanism required to drive the camshaft, typically a long chain or toothed belt with
greater the number of pistons, the more power that is produced, and the smoother the tensioners and idler pulleys to maintain precise valve timing, is much more complex.
running of the engine. They are almost exclusively petrol (gasoline) engines, operating on a
two- or four-stroke cycle. Two-stroke engines were once more common, but ever-stricter This kit has been designed to be straightforward and fun to build, and to provide a practical
emission controls have reduced their use in motorcycles. illustration of the principles of a real V-twin motorcycle engine. It is not intended to be a
replica of any specific real-life engine, and any similarities that exist are purely coincidental. It
The layout of the cylinders in a motorcycle tends to be ‘straight’ (a single row of cylinders has a transverse crankshaft, with the V-angle set at 90 degrees. A single overhead camshaft
running across the width of the bike), a ‘V’ (two rows of cylinders), or a ‘boxer’ arrangement on each cylinder is driven by its own toothed belt, operating the two valves per cylinder via
(two or more cylinders operating in a horizontal plane). rockers. Ignition timing is provided by an ignition system mounted inside the engine.
V-twin engines have existed since 1889, and had come into widespread use by the early part We hope you enjoy building your own V-twin engine and learning about the principles of how
of the 1900s. The term ‘V-twin’ is used to denote any twin cylinder engine in which the it operates.
cylinders are arranged at an angle between 0 and 180 degrees. The one exception is Ducati,
who refer to their 90 degree twin engine as an ‘L-twin’, because when mounted in the bike,
one cylinder is near horizontal and the other near vertical (so it looks like the letter ‘L’ when
viewed from the side).

Most V-twin engines have the pistons connected to a single crankpin, with the connecting
rods sitting side by side. A 90 degree V arrangement can, with the correct counterweights,
give perfect primary balance (in other words, there is no vibration arising from one rotation
of the crankshaft). An engine with an arrangement of less than 90 degrees is more compact,
at the expense of inferior mechanical balance and increased vibration.

V-twin motorcycle engines can be mounted with the crankshaft transverse to the frame (with
one cylinder in front of the other), or with the crankshaft longitudinal to the frame (with one
cylinder on either side of the frame). The transverse arrangement is the most common, and is
favoured by present-day manufacturers such as Ducati, Harley-Davidson, KTM, Aprilia and
most Japanese marques. Because the engine is narrower, it can be mounted lower in the
frame to improve handling, though cooling problems can be experienced with air-cooled
engines due to restricted air flow to the rear cylinder. The longitudinal crankshaft
configuration is used by Moto-Guzzi, and on some machines by Honda. Having the cylinders
protruding from either side of the bike makes air cooling more effective, though the
longitudinal crankshaft can induce a torque reaction if the throttle is opened or closed rapidly
and is particularly noticeable at low engine revs. Some taller riders can also find that their
knees hit the protruding cylinder heads, making riding more uncomfortable.

2 3
 INTRODUCTION NOTES AND ADVICE

Haynes International Motor Museum - All parts with the suffix ‘A’ are used to make the front cylinder and all parts with the
suffix ‘B’ are used to make the rear cylinder.
The Haynes International Motor Museum, at Sparkford in Somerset, is an educational
charitable trust, chaired by Haynes Publishing Group Founder Director, John Haynes OBE, - Identify the various parts by looking at the list of components and the corresponding
and established in 1985. The museum contains a collection of over 400 cars, motorcycles illustrations.
and automotive memorabilia, from the dawn of motoring to classics of the last 25 years.
The collection is housed in ten halls, along with a restaurant, gift shop and comprehensive - Use a sharp knife to trim any excess plastic from the components after they have been
conference facilities. The museum is open throughout the year, with the exception of removed from their carrier frames.
December 24th, 25th and 26th and January 1st. For further details see
- Take care not to over-tighten the screws as this may permanently damage the plastic.
www.haynesmotormuseum.com or call 01963 440804.
- Non-rechargeable batteries are not to be recharged.

- Rechargeable batteries are only to be charged under adult supervison.

- Rechargeable batteries are to be removed from the toy before being charged.

- Different types of batteries or new and used batteries are not to be mixed.

- Batteries are to be inserted with the correct polarity.

- Exhausted batteries are to be removed from the toy.

- The supply terminals are not to be short-circuited.

www.haynesmotormuseum.com

4 5
PARTS LIST PARTS LIST

3
Qty. Part Part No. Qty. Part Part No.
2 Gudgeon pins 1 1 Middle Transmission Case 26
2 Connecting rods 2 1 Ignition assembly 27 15
4 Piston halves 3 1 Gearbox assembly 28
2 Connecting rod bearing caps 4 1 Inlet manifold 29
1 Crankshaft 5 1 Carburettor top 30
4
1 Sump pan 6 1 Carburettor bottom 31
5
1 Lower crankcase 7 1 Air intake 32
1 Cylinder block 8 1 Air filter cover 33 29
2
2 Lower cylinder heads 9 1 Exhaust - front cylinder (a) 34
2 Small cylinder head plates 10 1 Exhaust - front cylinder (b) 35
18
2 Large cylinder head plates 11 1 Exhaust - rear (a) 36
4 Valve stems 12 1 Exhaust - rear (b) 37
2 Inlet valves 13 2 Engine side covers 38
2 Exhaust valves 14 2 Cam belts 39
4 Rocker arms 15 1 Gearbox gear 23
12
2 Upper cylinder head 16 1 Screwdriver
4 Rocker bearing caps 17 2 Cylinder head gaskets 17
4 Cams 18 65 Screws
22
2 Rocker covers 19 4 Valve springs
2 Crankshaft sprocket 20 2 Camshafts
2 Camshaft sprocket 21 2 Rocker shafts 21 13

2 Idler pulleys 22 1 Base

2 Timing alignment tool 23 20

2 Engine timing belt covers 24

4 Engine filler plates 25

14 1

6 7
PARTS LIST PARTS LIST
9

11

25
24

10

32

38 35 34
19

33
16

30

36 37
31

8 9
PARTS LIST PARTS LIST

Sump Pan (6) Middle Transmission Case (26) Head Gasket x 2 Cam Belt x 2 (39)

Camshaft (72mm) x 2

Valve Springs x 4 Rocker Shaft (43mm) x 2

Gearbox Assembly (28) Ignition Assembly (27)

Gearbox Gear

Cylinder Block (8) Base

10 11
 ASSEMBLING THE ENGINE ASSEMBLING THE ENGINE

Step 1 - Assemble the pistons and connecting rods Step 3 - Fit the lower crankcase to the sump 6
3
Push a gudgeon (wrist) pin through the Place the sump pan over the bottom of the lower
small end of a connecting rod. crankcase and secure with four screws.
Push two halves of a piston
together over the gudgeon Note: This will only fit one way.
pin and press firmly together.

Repeat for the other piston/rod 1

assembly. 7

Step 2 - Fit the piston/connecting Step 4 - Fit the sump to the base
rod assemblies to crankshaft
Fit the base to the sump pan and
The connecting rods attach to the secure with three screws.
crankshaft as shown.
Note: The legs are positioned so
In each case, place the connecting rod over that this will only fit one way.
the crankshaft, fit a bearing cap, and
secure with two screws.

Check that the piston/connecting rod

assemblies rotate freely around the 5
crankshaft.

12 13
 ASSEMBLING THE ENGINE ASSEMBLING THE ENGINE

Step 5 - Fit the piston/crankshaft Step 7 - Fit the valves to the lower cylinder heads
assembly to the cylinder block
10 11
Fit the cylinder head plates to the lower cylinder
Turn the cylinder block upside down. heads. Note that each head uses one
narrow plate and one wide
Hold the piston/crankshaft assembly and plate.
gently insert the pistons into the cylinders.
Note that the crankshaft will only fit into The narrow plate fits on the
the block one way. One of the flanges side of the head with the
has a step (refer to close up image) small hole, and the wide
that fits into a matching groove in the plate on the side with the
bearing surface in the block. large hole (the plates have
round studs that face downwards
You may need to rotate the crankshaft into the head).
slightly to move the pistons into position.
The plates must be pushed down
Lower the crankshaft until it rests on the 8 firmly so they clip into position. TIP: use the end of
bearing surfaces. the screwdriver to push the narrow plates into
9
position. Plates labelled ‘B’ should be fitted to
cylinder head ‘9B’ and plates ‘A’ to head ‘9A’.
Step 6 - Fit the cylinder block to the
Remove the 4 valve stems, 2 inlet valves and 2
lower crankcase
exhaust valves from the carrier frames. Note that
the exhaust valves are smaller than the inlet valves.
Turn the cylinder block the right way up, Carefully trim away any excess plastic with a sharp
with the crankshaft underneath. Hold the 12
knife.
ends of the assembly so the crankshaft
stays in position. Fit to the lower crankcase Slide a spring over a valve stem, and then insert the
and secure with four screws. The block will stem into the hole in the wide head plate. Gently
only fit one way. push the valve stem, compressing the spring until
the end of the stem sticks out of the bottom of the
DO NOT OVERTIGHTEN the screws. head. Carefully push an inlet valve on to the step.
Gently turn the crankshaft to make sure Note that the end of the valve stem has a step -
that it and the pistons move freely. If the push the valve until it touches the edge of the step.
crankshaft does not move freely, try
loosening the screws by a ¼ turn. DO NOT force the valve - these parts are delicate.

The studs in the narrow plate carry the exhaust

valves. Fit these in the same way as described
above for the inlet valves.

Repeat for the exhaust and inlet valves on the

other lower cylinder head. Check that the valves 13
move up and down smoothly.
14 15
 ASSEMBLING THE ENGINE ASSEMBLING THE ENGINE

Step 8 - Fit the rocker arms to the Step 10 - Fit the cylinder head gaskets
rocker shafts
15
Place the cylinder head gaskets over the
Remove the four rocker arms from cylinder block. There are pegs in the block
the carrier frame. Slide two arms on which match holes in the gasket to ensure
to each of the 43mm metal rocker correct alignment. Make sure the holes for
shafts exactly as shown in the the piston in each gasket align with the
diagram. hole in the block.

Note that the two rocker arm Each gasket will only fit on one half of the
assemblies are mirror images. Rockers ‘A’ Rockers ‘B’ block - they are not interchangeable.
Refer to the diagrams below.

Step 9 - Fit the rocker arm assemblies 17 Step 11 - Fit the lower cylinder heads to cylinder block
to the upper cylinder heads
Fit the lower cylinder heads to the
Lower the rocker arm assemblies on to the cylinder block. The pegs in the block
upper cylinder heads. Rocker assembly 'A' fit into the holes in the bottom of
should be fitted to upper cylinder head the heads to ensure correct
‘16A’ and assembly ‘B’ to head ‘16B’. alignment. They will only fit one
way. Secure each head with
Attach the bearing caps as shown, using four screws.
two screws for each, and then check that
the rocker arms move smoothly.
16

Rocker Assembly A - Rocker Assembly B -

front cylinder rear cylinder

16 17
 ASSEMBLING THE ENGINE ASSEMBLING THE ENGINE

Step 12 - Assemble the camshafts Step 14 - Fit upper cylinder

18 heads to lower cylinder heads
Remove the four cams, two labelled
A and B, and the other two labelled Fit the upper cylinder head
C and D from the carrier frames. Rear cylinder - cams C and D assembly “A” to the lower
Slide cams A and B on to one C head on the front cylinder and
D
camshaft. Each cam will only fit in secure with two screws. Be careful
one position - there is a flat surface that the longer arms of the rockers
on the inside of each which matches match the position of the valves - the
the flat surface on the camshaft. Front cylinder - cams A and B ends of the rockers must be positioned
over the tops of the valve stems.
Please also note the rib on
one end of each cam - Repeat Steps 13 and 14 for the rear
these must all face the cylinder.
same way. Repeat for
the two cams labelled
C and D.

A
B
Step 13 - Fit camshafts Step 15 - Fit crankshaft and camshaft sprockets
to lower cylinder heads
Fit the camshaft sprocket to the cylinder
Fit the camshaft with cams A and B to head marked “B” and the corresponding
the front cylinder made from parts crankshaft sprocket, as shown.
‘A’ (note that there is a “1”
engraved on the front of the
cylinder head). Carefully observe
the position of the ribs on
the cams.

Rear
cylinder
21

C D

20

18 19
 ASSEMBLING THE ENGINE ASSEMBLING THE ENGINE

Step 16 - Fit timing tool Step 18 - Fit timing belt cover

To complete this step, it is easiest if Fit the timing belt cover (marked 24R)
the engine is laid flat across your with five screws. Be careful
legs, with the sprockets facing not to dislodge the
upwards. Make sure that the 23 belt and pulleys.
rocker shaft on the front cylinder
(which will be facing downwards)
does not slide out when the engine
is laid flat.

Fit the timing tool to the crankshaft

and camshaft pulleys. You will need
to rotate the camshaft sprockets until 24R
the timing tool fits in the holes as
shown.

Note that the belt has chain links

moulded on one side - these should
face outwards. Step 19 - Fit second timing belt cover

Repeat steps 15 - 18 for the other side of the engine.

Step 17 - Fit timing belt and idler pulley

Fit the timing belt to the camshaft

pulley, and while maintaining gentle
tension, pass it around the crankshaft
sprocket. Finally, fit the idler
pulley so the belt
passes over it.

Carefully remove the

timing tool without 22
disturbing the belt.
24L

39

20 21
 ASSEMBLING THE ENGINE ASSEMBLING THE ENGINE

Step 20 - Fit the batteries Step 22 - Fit ignition assembly

Turn the engine upside down. Undo Fit the the ignition assembly (27) to the left
the screw securing the battery side of the engine and secure with three
compartment cover, open the screws. Note that the end of the crankshaft
compartment and fit 3 "AA" is D-shaped, which needs to engage with
batteries, taking care to match the corresponding D-shaped hole in the
the + and - markings. Replace the ignition assembly. You may need to
cover and turn the engine the right rotate the opposite end of the
way up. crankshaft until the two parts are aligned.
DO NOT force the parts together.

27

To check that the ignition

timing is correct, plug the
Step 21 - Gearbox/middle transmission case distributor lead into the base
28
(the plug will only fit one of
Fit the middle transmission case (26) the two holes). Identify the
to the gearbox assembly (28) and spark plug for the front cylinder
26 - it will have longer wires than
secure with three screws. Make sure
the one for the rear. Press the
the wires are routed through the slot
starter button on the base and
in the bottom edge of the gearbox rotate the free end of the
assembly. crankshaft counterclockwise.
The spark plug should illuminate
at, or just after, the point where
the camshaft sprocket reaches
the position shown far right
(ticked). If the spark plug
illuminates when the camshaft
sprocket is as shown right
(cross), remove the distributor
assembly, rotate the crankshaft
360 degrees, and then replace.

22 23
 ASSEMBLING THE ENGINE ASSEMBLING THE ENGINE

Step 23 Rear case assembly Step 25 - Fit spark plugs

Fit the spark plugs.

Slide the crankshaft gear on to the
Note that the leads to
large end of the crankshaft.
the front spark plug are
longer than those to the
Fit the gearbox/middle case assembly -
one at the rear.
it slides on to the bracket (circled) on
the rear of the engine. Secure to the
side of the engine with three screws
and to the ignition assembly with two
Step 26 - Assemble exhaust pipes
screws (arrowed). You may need to
twist the gearbox assembly slightly so Each exhaust pipe is made up of two
that it engages correctly with the parts. Assemble the front and rear
crankshaft gear. pipes as shown in 36
the diagrams.

35
37
34

Step 27 - Fit the exhaust pipes

to the engine

Fit the rear exhaust pipe to the

engine first, followed by the front
exhaust pipe. Note that there is a
Step 24 - Fit engine side covers slot in the front pipe that has to be
attached to the corresponding
Fit the engine side covers. bracket on the rear pipe.
These are a push fit into
the side of the engine.

38

24 25
 ASSEMBLING THE ENGINE ASSEMBLING THE ENGINE
30
Step 28 - Fit the head filler plates Small Filler Step 30 - Assemble the carburettor
25 Plate

Fit the cylinder head filler plates as Large Filler Fit the air intake (32) to the air filter
shown. The edges of the plates slide Plate cover (33) and secure with a screw. 32
down behind the edges of the
engine side covers. Note that for Place the air intake between the top
each head, you will need to use and bottom of the carburettor body 31
one small and one large (30 and 31), then fit this assembly to
plate. Also note that the the inlet manifold (29). Secure the
plate needs to be fitted parts together using a screw inserted
with the raised parts on through the base of the inlet manifold. 33
the top (circled).

29

Step 29 - Attach the head covers Step 31 - Fit the carburettor

Fit head covers to the top of the Attach the carburettor assembly to
upper cylinder heads and secure 19 the engine as shown. The ends of
each with two screws. Note the inlet manifold clip into the hole
that these will only fit one in each cylinder. Note that the air
way. filter cover should be on the same
side as the exhaust pipes.

26 27
 ASSEMBLING THE ENGINE HOW AN ENGINE WORKS

Step 32 - Attach sticker to base Basic Principles

To explain how a full-size V-twin works, we’ll use a simplified version of a real engine – our
Peel the self-adhesive label from its
model engine in fact. You can switch on your finished model as you read this explanation, and
backing and apply to the base as
it will help you to understand how a real engine works.
shown.
The crankshaft is called a crankshaft because it is a ‘cranked’ shaft – the shaft on our model
has one cranked section, and the piston/connecting rod assemblies connect to this. As the
crankshaft turns, the cranked section rotates around the centreline of the crankshaft, and this
allows the pistons to move up and down as the crankshaft turns.

When the piston moves down, it pushes the connecting rod down, which pushes against the
cranked part of the crankshaft, making the crankshaft rotate. This converts the up-and-down
movement of the piston into the turning movement of the crankshaft.

The engine’s crankshaft drives the transmission, which includes various different components
connected together to drive the bike’s rear wheel, making it move. A bike will normally have a
Step 33 - Starting the engine chain to drive the rear wheel, though some use a shaft.

Let’s look at how the engine works in more detail. We’ll look at just one cylinder of the engine.
Insert the two plugs into the base - A cylinder is the hollow cylinder inside the engine in which one piston moves up and down.
note that they are different sizes The piston has seals, called piston rings, around its edge, which aren’t shown on our model,
and will only fit one way. Press the and these seals stop gases passing round the sides of the piston.
red “Start” button. The engine will
run for approximately 30 seconds. When you press the starter button on the bike, the starter (a powerful electric motor, powered
by the bike’s battery) turns the crankshaft, moving the pistons up and down.

As a piston moves down from its highest position inside the cylinder (called ‘Top Dead Centre’,
or ‘TDC’), a mixture of petrol and air is sucked into the space inside the cylinder above the
piston. This is called the intake stroke.

The starter continues to turn the crankshaft, and as the piston moves back up towards the top
of its cylinder, the petrol/air mixture is compressed (squashed) in the space above the piston.
This is called the compression stroke.

As the piston reaches its highest point, a spark plug creates a spark above the piston, and this
spark ignites the petrol/air mixture, causing a small controlled explosion above the piston. The
explosion pushes the piston downwards, and this is called the power stroke.

Once the piston has reached its lowest point, it starts to move back up its cylinder, pushing the
burnt gases out through the top of the cylinder. This is called the exhaust stroke.

To summarise, the engine has four strokes: intake, compression, power and exhaust, or ‘suck’,
‘squeeze’, ‘bang’ and ‘blow’ to make it simpler. These four strokes make up the 4-stroke cycle.

28 29
 HOW AN ENGINE WORKS HOW AN ENGINE WORKS

The petrol/air mixture flows into the space above the piston, called the combustion chamber.
The mixture flows in through a small hole which is opened and closed by the inlet valve. The Valves closed Exhaust valve open
burnt gas flows out of the cylinder through another hole which is opened and closed by the
exhaust valve. The valves are normally held closed by springs, but as the engine turns, the Sparkplug
valves are pushed open in the correct order by the rocker arms, which are moved by the fires
camshaft. The rocker arm pushes the valve down against its spring, and as the rocker moves Exhaust
up, the spring pushes the valve closed. Petrol/air gases out
mixture
Let’s look at the 4-stroke cycle in more detail. ignites Piston forced Piston moves
down by up forcing
expanding exhaust
Inlet valve open Valves closed
gases gases out of
Exhaust cylinder
valve Inlet port
closed

Petrol/air
mixture Piston rises
Piston moves
compressing
down sucking
Connecting fuel/air
in fuel/air The 3rd stroke (Power) The 4th stroke (Exhaust)
rod mixture
mixture The very high pressure and temperature inside As the piston starts to move up inside the
the combustion chamber cause the petrol/air cylinder again, the exhaust valve opens to
mixture to break up into very fine particles, allow the burnt (exhaust) gas to escape
like a mist. These are perfect conditions for from the cylinder, and as the piston moves
burning a gas. All that’s needed to start the up the cylinder, it pushes the gas out
Crankshaft burning (or ‘combustion’ – a kind of through the exhaust valve. As the piston
rotation controlled explosion) is a spark. A very high reaches the top of the cylinder, the exhaust
electrical voltage supplied to the spark plug valve closes, the exhaust stroke ends, and
causes a spark to jump across the gap at the the 4-stroke cycle begins again with another
The 1st stroke (intake) The 2nd stroke (Compression) end of the spark plug. This ignites the intake stroke.
The piston starts off at the top of the At the start of the compression stroke, the petrol/air mixture, and starts the combustion.
cylinder. The exhaust valve is closed, and the piston is at its lowest point inside the The force of the controlled explosion and the
inlet valve is open. As the crankshaft turns, cylinder, and the inlet and exhaust valves are expanding gases forces the piston
and the piston moves down inside the closed. The crankshaft continues turning, downwards, which pushes the crankshaft
cylinder, petrol/air mixture is sucked in and the piston moves upwards. As the piston round. During the power stroke, three things
through the inlet valve. When the piston moves upwards, it squeezes (compresses) the happen to the petrol/air mixture – it ignites,
reaches its lowest point inside the cylinder, petrol/air mixture, and this increases the combusts (burns) and expands. The expansion
the cylinder is filled with petrol/air mixture, temperature of the mixture very quickly. of the gas pushes the piston down, which
and the inlet valve closes. This is the end of When the piston reaches its highest point, transfers the power to the crankshaft. When
the intake stroke. the mixture is fully compressed, and this is the piston reaches its lowest point inside the
the end of the compression stroke. cylinder, this is the end of the power stroke.

30 31
 HOW AN ENGINE WORKS BASIC ENGINE TERMS

The model engine Bore – A term used to describe the diameter Crankcase – The area of the cylinder
You can see how the 4-stroke cycle works by starting your model engine, and watching how of a cylinder in an engine. block below the pistons, which houses the
the components inside move. Watch how the camshaft and rockers move the valves as each Breather – An opening or valve that allows crankshaft.
piston moves up and down inside its cylinder. If you watch the piston in one cylinder, you air or fumes out of the engine, or fresh air Crankshaft – A cranked metal shaft that
should be able to recognise the four strokes – watch the valves, and see if you can tell which into the engine. changes the up-and-down motion of the
stroke is which. Remember that: Cam belt – See Timing belt. pistons and connecting rods into rotary
• On the intake stroke, the piston moves down, the inlet valve is open, and the exhaust motion.
Cam follower (tappet) – A component
valve is closed. fitted between the camshaft and a valve to Cylinder – A metal tube in the engine, in
• On the compression stroke, the piston moves up and the inlet and exhaust valves are closed. operate the valves. which a piston slides.
• On the power stroke, the piston moves down and the inlet and exhaust valves are closed. Cylinder block – The main engine casing,
Camshaft – A rotating shaft driven from the
• On the exhaust stroke, the piston moves up, the inlet valve is closed, and the exhaust which houses the cylinders, crankshaft,
crankshaft, with cams that push the valves
valve is open. open. pistons and connecting rods.
Catalytic converter – A device fitted in the Cylinder head – The casing at the top of the
The exhaust valves are both positioned on the outside of each cylinder, next to the exhaust engine that houses the valves and valve gear.
exhaust system that reduces the amount of
pipes, and the inlet valves are on the inside of each cylinder, next to the inlet The cylinder head is bolted to the cylinder
harmful gases released into the atmosphere.
manifold/carburettor. block.
Clutch – A part that allows two separate
rotating components to be coupled together Cylinder head gasket – The gasket that
You’ll notice that the two cylinders in the model engine are on different ‘strokes’ – watch how makes a seal between the cylinder head
the pistons move as the crankshaft turns, and you’ll see that the position of the front piston is smoothly, without the need for either
component to stop moving. and the cylinder block.
slightly ahead of the piston in the rear cylinder. You can tell which piston is about to start its
Combustion chamber – A shaped area into Dipstick – A metal or plastic rod used to
power stroke, because the spark plug will fire (the bulb will light) in the cylinder head above
which the fuel/air mixture is compressed by check the engine oil level.
the piston which has just reached the end of its compression stroke and is about to start its
power stroke. the piston, and where the mixture is ignited. Distributor – A device used to distribute the
The combustion chamber may be in the ignition HT circuit current to the individual
cylinder head, or sometimes in the top of spark plugs.
the piston. DOHC – Double Overhead Camshafts. An
BASIC ENGINE TERMS Compression ratio (CR) – A term to describe engine with two camshafts, where one
the amount by which the fuel/air mixture operates the inlet valves, and the other
is compressed as a piston moves from the operates the exhaust valves.
Here’s a list of common terms connected Battery – A ‘reservoir’ that stores electricity.
bottom to the top of its travel. Drivebelt – A belt, usually made from rubber,
with a car engine, with simple explanations Provides the power to start the engine, and
of what they mean. power for the electrical systems when the Connecting rod (con rod) – A metal rod used to transmit drive between two pulleys or
engine’s stopped, and is charged by the in the engine connecting a piston to the sprockets. Often used to drive the camshafts
Air filter – A paper or foam filter that
alternator when the engine’s running. crankshaft. The connecting rod transfers and engine ancillaries.
removes dirt from the air that’s sucked into
the up-and-down motion of the piston to Emissions – Harmful substances (gases or
the engine. Bearing – A metal or other hard-wearing
the crankshaft. particles) released into the atmosphere from
Alternator – An electrical generator driven surface that another part moves against. A
bearing is designed to reduce friction and Coolant – A mixture of water and a car’s engine.
by the engine. It provides electricity for the
wear, and is usually lubricated with oil or antifreeze, used in a car’s engine cooling Emissions control – A way of reducing the
car’s electrical system when the engine’s
grease. system. emissions released into the atmosphere.
running, and to charge the battery.
Big-end – The lower end of a connecting Coolant (water) pump – A pump driven by Engine management system – A system
Antifreeze – A fluid that’s added to water
rod attached to the engine’s crankshaft. It the engine that pumps the coolant around which uses an electronic control unit to
to produce engine coolant. The antifreeze
has a bearing, and transmits the movement the cooling system. control the ignition system and fuel
stops the coolant freezing in cold weather,
and prevents corrosion inside the engine. of the connecting rod to the crankshaft. injection system, improving engine efficiency
and reducing emissions.

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HOW AN ENGINE WORKS BASIC ENGINE TERMS

Exhaust manifold – A ducting used for Inlet manifold – A ducting, usually made Timing belt (cam belt) – Toothed drivebelt,
directing the exhaust gases from the of metal or plastic, which directs the air, or used to transmit drive from the crankshaft
engine’s cylinder head into the exhaust fuel/air mixture into the engine’s cylinder to the camshaft.
system. head. Top Dead Centre (TDC) – The exact point
Firing order – The order in which the Mixture – The fuel/air mixture burnt by an when a piston is at the top of its stroke.
pistons in the cylinders of an engine reach engine to produce power. Turbocharger – A device that forces air into
their firing points. Oil filter – A renewable filter that removes the engine. This pushes more fuel/air mixture
Firing point – The instant at which the dirt from the engine oil. into the engine and increases the engine’s
fuel/air mixture in the cylinder of an engine Piston – Cylindrical component which slides power.
ignites in the combustion chamber. in a close-fitting cylinder. The pistons in an Twin-cam – Abbreviation for twin overhead
Flywheel – A heavy metal disc attached to engine compress the fuel/air mixture, camshafts – see DOHC.
one end of the crankshaft in an engine, transmit power to the crankshaft through Valve – A device that opens and closes to
used to smooth out the power pulses from the connecting rods, and push the burnt stop or allow gas or liquid to flow.
the pistons. gases out through the exhaust valves.
Valve clearance – The clearance between
Four-stroke – A term used to describe the Piston ring – A hardened metal ring that the top of a valve and the camshaft.
four operating strokes of a piston in an fits in a groove running around a piston.
Valve lifter – See Cam follower.
engine. The piston ring ensures a gas-tight seal
between the piston and the cylinder. 16-valve – A term used to describe a
Fuel injection – A method of injecting a four-cylinder engine with four valves in each
measured amount of fuel into an engine. Radiator – A cooling device, usually
cylinder, usually two exhaust and two inlet
Fuel injector – A device used to inject fuel positioned at the front of the car, through
valves.
into an engine. Some engines use a single which the hot coolant is passed. As the car
moves forward, the airflow cools the Vee-engine – An engine design where the
fuel injector, whilst some use one fuel cylinders are arranged in two rows forming a
injector for each cylinder of the engine. coolant in the radiator.
‘V’ when viewed from one end. For example
Gasket – A material used between two Rocker arm – A lever used in an engine’s
a V8 has two rows of four cylinders each.
surfaces to give a leakproof joint. valve-operating mechanism which rocks on
a pivot, with one end moved up and down
Head gasket (cylinder head gasket)– A
by the camshaft, and the other end
gasket fitted to provide a leakproof seal
operating a valve.
between an engine’s cylinder block and
cylinder head. Spark plug – A device that provides the
spark in a petrol engine’s combustion
Ignition coil – An electrical coil that
chamber to ignite the petrol/air mixture.
generates the high voltage needed in a
petrol engine ignition system to fire the Starter motor – An electric motor used to
spark plugs. start the engine.
Ignition system – The electrical system that Stroke – The total distance travelled by a
controls the spark used to ignite the single piston in a cylinder when it moves
petrol/air mixture in a petrol engine. from the bottom to the top of the cylinder.
Ignition timing – A measure of the instant Sump – The main reservoir for the engine
in the cylinder firing cycle at which the oil. Bolted to the bottom of the engine.
ignition spark (provided by the spark plug) Tappet – See Cam follower.
happens in a petrol engine.

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