Contents

Page

Preface ' 7

Chapter 1 — Introduction 9

Chapter 2— The cylinder head 13Chapter 3 — Porting and cylinder scavenging 27Chapter 4 — The exhaust 76Chapter 5 — Carburation 93Chapter 6 — Ignition 125Chapter 7— The bottom end 143Chapter 8— Lubrication and cooling 166Chapter 9— Power measurement and gearing 174

Appendix I — Introduction 187

A Motocross modifications 187B Enduro modifications 198C Road race modifications

202

Appendix II— Table of useful equivalents 219Appendix III—Speciality suppliers • 220

Index 222

Preface

FROM A very humble beginning, the two-stroke internal combustion engine hasnow been developed to a degree that was not thought possible just a few years ago. Iam sure even the engineers who have stood by the two-stroke principle for so long findit staggering that this mechanically simple device can produce as much power as it doestoday, with relative reliability.Originally, I looked upon two-stroke engines with contempt. They made a horriblering-ding noise, nothing like the beautiful note of four-stroke racing engines. Theyemitted a blue haze from their tailpipes too, which appeared unsightly, long before anyof us heard of the word pollution. On hot days these engines seized with monotonousregularity. Difficult starting, flooding and plug fouling seemed the order of the day.Consequently I wrote off two-strokes, convinced I would never lower myself todevelop one of these unreliable little beasts in my workshop. But that all changed whentwo of my friends bought themselves 250cc Bultaco Pursang motocross bikes andinsisted I prepared them. I took up the challenge and was rewarded with the knowledgethat a ring-ding I had developed came home 3rd in the National MotocrossChampionship with a B grade rider on board.From then on the challenge has not abated as I have strived to unravel the mysteryof what makes a two-stroke tick. Instead of looking on the two-stroke with contempt, Inow view this little marvel with fascination. Four-stroke engine development has justabout reached its peak, but there is much yet to be learned about the two-stroke power

unit.

It is my hope that this book will assist the enthusiast involved in motocross,enduro, desert, road or go-kart racing to develop and tune his two-stroke engine forhorsepower and reliability.

MaitlandNew South Wales