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Amsnow
New Engine Testing and Lead Time
Q:What kind of testing goes into an engine before it is put into a sled for public purchase. How long is the lead time from conception to availability. - AmSnow.com user U.S. Marshall
AC engineers answer: A new engine design starts with a decision from Arctic Cat that a new engine is needed to successfully compete in the market. Arctic Cat then works with Suzuki to establish the basic dimensions of this engine - bore, stroke, compression ratio, port layout and so on. These specifications are then given to Suzuki and engineering drawings and prototype tooling are completed. Suzuki then provides us with a small number of prototype engines of the requested dimensions.
The prototype engines go through an entire fall and winter season of complete development on one of our engine dyno's, along with many hours of field development and calibration, and many hours of durability testing both in the field and in one of our durability labs. Arctic must establish dimensions and parameters such as cylinder port configuration, combustion chamber shape, piston shape design, complete intake and exhaust development, and fuel and clutch calibrations. Average development time for the prototype phase is 1,600 hours of dyno time, and 1,500 hours of field development and durability testing.
After the prototype has been developed, the new engine specifications are finalized with Suzuki. Suzuki then prepares drawings and tooling that are reviewed by both Arctic Cat and Suzuki. Production tooled engines are then provided by the following fall, based on all specification and changes arrived at through the prototype development phase. This engine is referred to as the Production Proto and it again goes through an entire development phase of final cylinder port, compression ratio, intake and exhaust system calibrations, along with fuel system mapping and clutch calibration.
This engine phase also focuses heavily on durability testing. The production proto phase of a new engine must be tested for 5,000 miles on 8-10 chassis packages at low and high altitudes. The average development time for this phase is 1,000 hours of dyno time, and 900 of field development and calibrations.
The next engine phase is called the Pilot engine. This is the actual production engine built in small quantities as a last quality check of production dimensions and specifications. These engines usually arrive in late spring or summer about 3 months prior to the actual production of that snowmobile model. The Pilot engine is carefully measured and dynoed for correct calibration, specifications and performance. In some cases, this Pilot engine will have arrived in time to be installed in a production-intent chassis and field tested.
The measurement and verification of the Pilot engine usually takes 200 hours of dyno and some field time.
The final phase of a newly developed engine is the actual production engine. These arrive exactly as the Pilot engine, but in large production quantities. The Production engine is again measured, dynoed and verified prior to full production. This measurement and verification generally takes 40 to 50 hours.
The total time from conception to full production of a new engine will take 30-33 months of development.