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In Europe the next level of emission regulations for motorcycles, Euro IV, is on the verge of introduction, followed by Euro V around 2021. Together with the new emission regulations, the ECE R 40 testing cycle will become obsolete and the more realistic World Motorcycle Testing Cycle (WMTC) will be introduced. Current catalytic solutions for gasoline engines consist of so-called three way catalysts (TWC) that are able to reduce the emissions of CO, NOx and hydrocarbons (HC) below the regulatory emission limit. These catalysts mostly contain platinum (Pt), palladium (Pd) and rhodium (Rh) in different concentrations and ratios. Another important component is the so-called oxygen storage material (OSC) which compensates for the fluctuations in lambda during acceleration and deceleration. Currently existing catalyst formulations must be modified to fulfil the more stringent emission limits with simultaneous consideration of a more realistic test cycle.

Looking at upcoming emission legislations for two-wheelers, it is quite obvious that the fulfilment of these targets will become one of the biggest challenges within the engine development process. The gradual harmonization of emission limits for two-wheelers with existing automotive standards will subsequently lead to new approaches regarding mixture preparation and exhaust gas aftertreatment. Referring to these future scenarios, a state-of-the-art in development of catalytic converters for two- or three-wheeler applications should be presented. After choosing a suitable test carrier, which has already been equipped with EFI components including an oxygen sensor for λ=1 operation mode, a basic injection system calibration was used to optimize the combustion process. Based on this setup, a variable exhaust system was manufactured to be able to integrate different catalyst configurations.

Current catalytic formulations for motorcycles consist of so called three way catalysts (TWC) that are able to reduce the emissions of carbon monoxide (CO), nitrous oxides (NOx) and hydrocarbons (THC) below the regulatory emission limit. These catalysts mostly contain platinum (Pt), palladium (Pd) and rhodium (Rh), also called platinum group metals (PGM) in different ratios and concentrations. Another important component is the so-called oxygen storage material (OSC) that is compensating fluctuations in lambda during acceleration and deceleration. Currently existing catalyst formulations must be modified to fulfill the more stringent emission limits with simultaneous consideration of a more realistic test cycle. In this paper we will present the modification of an existing catalytic formulation for a 690 cm3 motorcycle from model year 2012. The motorcycle is equipped with a quick-change muffler to be able to compare different formulations in a simple way.