The Public Authority for Applied Education & Training

College of Technological Studies

Automotive and Marine Mechanics Technology Department

Final Report

YAMAHA Co.

Prepared by: Homod Khalid Aawad Al-Enzi

Supervised by: Eng. Eissa Al-Yaaqoub, Eng. Salah El-Bloushi
 Acknowledgment

I extend my sincere thanks to the Public Authority for Applied

Education and Training, Sultan Al-Salem Company (YAMAHA),
and also Engineer Salah Al-Bloushi and Engineer Eissa Al-
Yaaqoub for giving all students confidence and ensuring that
students gain valuable information.
Table of Contents

1. Introduction

2. Engines

2.1. Engine Types

2.2. Difference between Engine Types in term of working

mechanism

2.3. Difference between the two engines

2.4. Advantages & Disadvantages of the Engines

2.5. Engine Parts (Fixed & Moving)

2.6. Propeller Types

2.7. Water & Cooling cycle

2.8. Fuel Cycle

2.9. Basics of Engine Installation

2.10. Thermostat

2.11. Periodic Maintenance

2.12. Spark Plugs

3. Activities Carried out during training period

4. References
List of Figures

1. Figure (1) YAMAHA Head Office in Kuwait

2. Figure 2 Replacement of Flexible Coupling 55 hp

1. Introduction
Brief about YAMAHA

The history of this huge

company dates back to the
year 1887, when the
company's founder,
Torakusu Yamaha,
manufactured a harmony
key machine and later
received several orders to
manufacture it.
YAMAHA is one of the
largest companies in
reliance and spending on
its employees.
The company adopts
young children from the time they complete their initial education by
enrolling in Yamaha University, which was established to develop the
level of the company’s employees until they work in the company’s
branches around the world.
After studies and experiments, it was concluded that the reason for the
quality of Yamaha products is the meticulous specialization among its
employees, as one product requires dozens of engineers and
technicians specialized, for example (in the product’s body, strings,
keys, etc.).
Speaking of the origin of Yamaha, it is a Japanese company. Yamaha
was founded on October 12, 1887, and is one of the oldest
manufacturers of engines and motorcycles around the world.

The most important products of the Japanese company Yamaha in the

field of engines and equipment are as follows:
1. Musical devices
2. Audio and visuals
3. Electronics
4. Motorcycles
5. Vehicle engines
 2. Engines
2.1. Engine Types

- 2-Stroke
- 4-Stroke

2.2. Difference between the engines types in terms of the

working mechanism

- 2-Stroke
A two-stroke engine combines the compression and ignition steps on
the upstroke and the power and exhaust steps on the down stroke.
This process requires fewer moving parts for easier maintenance, but
it does provide less torque.

The two-step process includes:

1. Up stroke (ignition/compression): The piston goes up, air and

fuel enter the crankcase. The fuel-air mixture is compressed and
ignited.
2. Down stroke (power/exhaust): Once the fuel is ignited, the piston
is pushed down, and the exhaust is expelled.

- 4-Stroke

Four-stroke engines are fuel-efficient and operate in four steps:

1. Intake: The intake valve is open, and fuel is drawn in with a

downward stroke.
 2. Compression: As the piston moves upward, the fuel is
compressed.
3. Power: After the fuel is compressed, it is ignited to produce the
engine’s power.
4. Exhaust: The exhaust valve opens, and the exhaust gases exit the
cylinder.

2.3. Difference between the two Engines

The main difference between a 4-stroke engine and a 2-stroke engine

is that a 4-stroke engine goes through four stages, or two complete
revolutions, to complete one power stroke, while a 2-stroke engine
goes through 2 stages, or one complete revolution, to complete one
power stroke. This means a 2-stroke engine can potentially produce
twice as much power as a 4-stroke engine and also weigh less.

- 2-Stroke

 It does not have a lubrication system, but oil is added to the fuel
 It has openings for exhaust to enter and exit
 Most engines are air cooled

- 4-Stroke

 It has a forced lubrication system

 It has intake and exhaust valves
 It has dividing gears and a camshaft
 Most engines are water cooled
2.4. Advantages & Disadvantages of the Engines

2.4.1. Advantages of the Two Engines

- 2-Stroke

There are many benefits to using a two-stroke engine. Some

advantages include:

1. A two-stroke engine weighs less compared to a four-stroke

engine and requires less space.
2. The engine’s turning movement is even since it takes one
power stroke for each crankshaft revolution.
3. This engine’s design is simple due to the lack of a valve
mechanism.

- 4-Stroke

Using a four-stroke engine offers a variety of benefits. Some of

these advantages include:

1. Four-stroke engines yield higher levels of torque at a lower

RPM during operation.
2. A four-stroke engine only consumes fuel once every four
strokes, making it a more fuel-efficient engine option.
3. Four-stroke engines give off less pollution because they do
not require oil or lubricant mixed in the fuel.
 2.4.2. Disadvantages of the Two Engines

- 2-Stroke

1. Two-stroke engines consume more fuel, and only a small

amount of fresh charges mix with gasses from the exhaust.
2. You may experience a high amount of vibration or noise
during operation.
3. This engine has a shorter life span since it incurs increased
wear and tear.

- 4-Stroke

1. The additional components in the four-stroke design make

these engines heavier compared to the two-stroke version.
2. A four-stroke engine contains more parts and valves, making
repairs and maintenance more expensive.
3. Since it only receives power once every four rotations of the
piston, this design is less powerful than a comparable two-
stroke engine.

2.5. Engine Parts (Fixed & Moving)

 Fixed Parts

1. Engine Head Cover

2. Engine Head
3. Gasket
4. Engine Body
5. Crank Case
 6. Intake & Exhaust manifold

 Moving Parts

1. Piston
2. Piston Ring
3. Pressure Ring
4. Oil Chamber
5. Connect Rod
6. Crank Shaft
7. Cam Shaft
8. Valves
9. Flywheel
10. Timing Belt

2.6. Propeller Types

2.6.1.Steel

 For Big Engines 75 hp and above

 Size 19 and 21 inch
 Providing Speed more than Aluminum Type.
 3 or 4 or 5 blade

2.6.2.Aluminum

 For Engines 9.9 to 60 hp.

 Size 12 & 13 inch.
  Speed less than Steel Type.
 3 or 4 blade.

2.6.3.Copper

 2 or 3 or 4 or 5 blade

2.7. Water & Cooling Cycle

1. Water enters from gear

2. Then it goes through flexible coupling
3. Then water is pushed to the top cooling fridge
4. Then it will enter channels for each piston and it will cool
the engine

2.8. Fuel Cycle

- 2-Stroke

1. Fuel flows from fuel tank to filter by a manual pump.

2. Then from filter to Carburetor
3. Then it moves to the injection valves.
4. Then fuel enters the cylinders, so engine will start
5. After that the combustion product will go through the
exhaust.
 - 4-Stroke

1. Pumping gasoline from the tank once (manual pumping)

2. Then it enters the gasoline filter
3. Then it moves to the gasoline pump
4. Then it moves to the sprayer
5. And then to the pistons
6. The engine is started
7. Then it becomes combustion and exits through the
exhaust

2.9. Basics of Engine Installation for Boats

Types

 Short Engine mounting 21 inch

 Long Engine mounting 26 inch
 Ultra long Engine mounting 30 inch

2.9.1. Single Engine

Measurement shall be taken for the boat specially the engine

mounting at the backside of the boat.
Engine shall be installed at the center (Engine must be
equalized from both sides right and left).
 2.9.2. Double Engine

Difference between 2-Stroke and 4-Stroke distance between

the two engines shall be:

2-Stroke 30 cm
4-Stroke 36 cm

2.9.3. Three Engines

If the available engines mounting space is big so it is better

to provide 36 cm between the engines

If the available engines mounting space is small so it is

better to provide 35 or 34 cm between the engines
Before installation, engines should be tested for moving
around without touching each other.

2.10. Thermostat

This piece expands and contracts

with heat, thus opening or closing
the cooling cycle

 2-Stroke

- Thermostat could be cancelled

due to high temperature.
 - Or due to rapid increase in engine temperature
- Gasket is provided to prevent leakage

 4-Stroke

- Thermostat installation is a must due to non-existence of

gasket.
- Its function is to allow water to enter
- Stabilize the engine temperature

2.11. Periodic Servicing

 2-Stroke

1. Spark plugs.
2. Gear oil (90)
3. Washer

 4-Stroke

1. Spark plugs
2. Gear Oil
3. Engine Oil
4. Filters
2.12. Spark Plugs

This piece is used to ignite the

mixture consisting of gasoline
and air inside the combustion
chamber of the engine

 Normal Plug

1. An electric explosion is used between the two electrodes

2. The teeth are short
3. It consumes less energy

 Laser Plugs

1. Laser technology is used to generate sparks through the

interaction of light
2. The teeth are long
3. It consumes more energy
3. Activities carried out during the training period
 Installation of 200 hp Engine 2-Stroke on a 25 feet boat

Installation Procedures:

1. Measure the boat engine

mounting space and place the
engine on the center of the boat
backside engine mounting
space.
2. First, the power steering is
installed in the engine
3. Then the stabilizer is installed
4. Install the engine at the boat
patch.
5. After installing the machine, new measurements are taken to
ensure its correct location
6. The boat body is drilled and then bolts are installed for the engine
to attach to the boat body
7. Then we go up to the top of boat body and install the steering
complex and then the control
8. The cable is installed for the control and connected to the engine:
1- Main cable 2- rpm and trim cable
9. The boat is drilled from bottom 2 holes
10.The steering oil is filled, and then vented
11.Then the battery head is installed, and the last step is to start the
engine
 Overhauling of 200 hp Engine 2-Stroke with
replacement of gear flexible coupling.

Overhauling Procedures

1. Engine cover to be removed

2. Dismantling of all carburetors (6 Nos.)
3. Cleaning of carburetors
4. Then re-installed
5. Dismantling of the old Gear
6. Replacement of Gear flexible coupling
7. Changing of Gear oil with washers
8. Installation of the new 2-Stroke gear.
9. Replacement of Spark Plugs.
10. Replacement of Gasoline Filter.

 Replacement of gear flexible coupling 55 hp.

Procedures:

1. Dismantling of the gear

2. Dismantling of flexible coupling cover
3. Replace the old coupling with a new one
4. Replacement of bolts and washers for gear oil
5. Changing of gear oil
6. Replacement of washers
7. Re-installation of the gear.
 (Figure 2 Replacement of Flexible Coupling 55 hp.)

4. Safety precautions at the Entity

1- Existing of Fire Extinguishers at the Workplace

2- Availability of personnel protective tools (PPE) like:
 Safety Shoes
 Safety Goggles
 Coveralls
5. References

3- https://primesourceco.com/latest-news/the-difference-between-a-2-
stroke-and-4-stroke-engine/

4- http://www.thecartech.com/KnowYourCar/VS/four_and_two_strokes_
files/four_and_two_strokes.aspx