Low cost Low CC Bike

1. Design and
fabrication of Low
cost low cc bike

2. TEAM MEMBERS:
 R.Micheal ashwanth
 M.Ponmani kumar
 K.Jayasurya
 S.Vikram
 M.Ponvijay
 S.Sri ram prabhu
III YEAR AUTOMOBILE DEPARTMENT
K.L.N.C.E
Guided by:-
R.VIJAYABALAN AP2/AUTO ENGG.

3. Abstract
 One of the defending factors in Indian roads is TRAFFIC
 we designed a smaller sized bike using a low cc i.e. 80cc
engine .
 Vehicles which used 80cc engine in the past were only
74.8 – 76 .hence we did reboring process which came nearly to 80 i.e.79.6cc.
 The advanced growth and technologies in automobile industry gave us more idea of
developing our own new bike.

4. S.NO TECHNICAL SPEC. OUR MINI BIKE BAJAJ M80
1. Engine displacement 80.00 cc 74.08 cc
2. Overall length 1536.7 mm 1920 mm
3. Overall width 589.3 mm 720 mm
4. Overall height 863.6 mm 1025 mm
5. Overall weight 60 kg 80 kg
6. Wheel base 1193.6 mm 1170mm
7. Ground clearance 160 mm 135mm
8. Frame material Mild Steel N/A
9. Suspension
• Front
• Rear
Rack handle
Mono suspension
Hydraulic shock
absorber
Variable rate coil spring
10. Brake
• Front
• Rear
Drum
Drum
Drum
Drum
11. Fuel tank capacity 5 litres 3.5 litres
12. Transmission 3 speed gearbox 3 speed gearbox
13. Tires
• Front
• Rear
16 inch diameter
Spokes wheel
Spokes wheel
17.4 inch diameter
Spokes wheel
Spokes wheel

5. Design drawing

6. Detailed drawing
ALL DIMENSIONS ARE IN mm
Side view
Front view

7. Final view

8. Chassis design

9. Original chassis

10. ENGINE DESIGN
 Engines with 80cc are few; we searched wide range of
engines within 80cc. Then we finalised with 80cc m80
engine.
 Vehicles which are 80cc engine in the past were only
74.8 – 76 .hence we did reboring process which came
nearly to 80 i.e.79.6cc.

11. The specification of the engine is given below
Type Air Cooled
Stroke (2/4) 2 Stroke
No. of cylinders Single Cylinder
Bore x stroke 42.6 mm x 42 mm
Displacement 80cc
Maximum Power 5.5 BHP @ 6000 rpm
Max. Torque 6.3 kgm @ 4500 rpm
Start Kick
No. of Gears 3-speed gears

12. Chassis
 The engine and chassis contribute a major factor in the
weight of a vehicle. The bike should not exceed the
weight of 80kg.
 . We selected M.S(mild steel),which is known for its
low weight and high strength.
 We selected the diameter of 1.034 inches, which we
hope can withstand the load acting on the vehicle
chassis

13. Overall design report
 The design of the vehicle proves to be simple yet
efficient.
 Made of mild steel.
 It has an aesthetic look.
 Hollow pipes used for the chassis.
 User convenient.

14. Transmission system
 Our mini bike has a 3-speed manual transmission
system which is the main advantage.
 When the load acting is heavy ,at some point the
speed of the bike decreases but the transmission
system varies the speed on any load given.

15. Special features
 Rear mono suspension fitting
 Less weight
 Fully covered fuel tank
 Kill switch
 Ignition Resistor

17. Rear mono suspension fitting
Normally the mono suspension is placed as inclined position, but
in our design it is fitted horizontally ( detail of mono suspension
working).

18. Suspension
mounting

19. Kill switch
 A kill switch is a safety mechanism used to shut off a
device in an emergency situation in which it cannot be
shut in a usual manner.
 Many kill switches feature a removable barrier or other
protection against accidental activation.

20. Less weight
Tubular MS rods are used.
Chassis Weight=14.6 kg
Overall weight of the bike = 60 kg

22. Rigid and closed fuel tank
position
 This tank is a rigid tank .
 This tank is installed in a compartment designed to
accommodate the tank.
 This tank has been implicated in such a way that it
cannot be damaged.

24. Side Stand ignition
 This is an main advantage of our bike i.e. the vehicle
does not start till the stand is fully settled.
 This actually works as an engine immobilizer.

25. Resistance calculation of bajaj m80
Weight of the bike = 80 kg
W = 784.8 N
Power, p =
Velocity, v =
V =
V = 70 km/hr (Top Speed)
Total resistance, R = air resistance + rolling resistance
= a Av2 +krw
Where, ka = air resistance for medium passenger car
A= frontal area, v= velocity, kr= for muddy road, w= weight
ka Av2 = 0.031× 20 × (70)2
= 3038
krw = 0.015 × 784.8
= 11.77
RESISTANCE
CALCULATION
R = 3038+11.77
= 3049.77N

26. Total resistance, R = air resistance + rolling
resistance
= a Av2 +krw
Resistance calculation of LC &
LCC Bike
V = 60 km/hr
KaAV2 = 0.031× 20 × (60)2
= 2232
KrW = 0.015 × 588.6
= 8.829
R = 2232+8.829
= 2240.829 N

27. Difference between the two resistances is
808.95 N
Hence it proves that our bike is more efficient than the existing model.
The calculated brake power (BP) produced in our LC LCC bike is
5.5 bhp @ 6000 rpm .
But the brake power produced in BAJAJ M80 is
4.7 bhp @ rpm.

28. Tests and reports
Our bike Bajaj M80
Engine displacement 80cc 74.08cc
Max.power 5.5 bhp @ 6000 rpm 4.7 bhp @ 6000 rpm
Max.torque .65 kgm @ 4500 rpm .55 kgm @ 4500 rpm
Top speed 60 kmph 70 kmph
Mileage 50 kmpl 55 – 60 kmpl
Weight 60 kg 80 kg

29. ESTIMATION REPORT:
This report will give the total cost of the material and parts used
to complete
the mini-bike successful.
Components:
• Engine -Rs.3500
•Frame material - Rs.3000
•Wheel (400 × 10) 2Nos. -Rs.3000
•Transmission system -Rs.1500
•Suspension
• Front -Rs.600
• Rear -Rs.900
•Brake
• Front -Rs.200
• Rear -Rs.200

30.  Fuel tank - Rs. 600
 Accelerator cable - Rs.200
 Brake cable - Rs. 200
 Handle bar - Rs.200
 Side stand - Rs.300
 Mud guard (f & r) - Rs.400
 Brake pedal - Rs.250
 Seat - Rs.400
 Stay - Rs.450
 Electrical system - Rs.1500
 Painting - Rs.1000
 Engine boring - Rs.1000
 Miscellaneous(nuts, bolts, tools) - Rs.600
 Welding -Rs.4000

31. THANKYOU