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Indian two wheeler market is one of the largest and highly competitive in the world. Indian scooter segment grows at a pace of around 30% YOY. The stiff competition among OEM’s to increase the market share with fuel efficient and high performance products pushes development and calibration engineers to burn the midnight oil to concoct innovative methods to design technology boosted product. Customer expectations are always high in terms of fuel economy, drivability and NVH. Due to higher level of complexity involved in CVT (Continuously Varying Transmission) engine, it is difficult to optimize for achieving best of NVH characteristics along with Fuel Economy, drivability and reduced exhaust emission. This paper describes the experiment conducted during the development of 110cc CVT four stroke scooter engine. The development and calibration of this scooter was mainly based on real world usage pattern (RWUP).

Scooter segment growth is tremendously increasing in India. The increased competition challenges automotive manufacturers to deliver the high quality and high reliable product to the market. Higher reliability involves increased durability testing which involves time and cost. Stress testing a part of durability is initially conducted on prototype vehicles for structural design validation and then later on production units to ensure its structural integrity. The obtained data from the tests can be used for future structural design improvements. Scooters with small tires, suspension limitations transfers more loads to structure, challenges engineers to design robust structure without compromising on weight much. It is necessary to look at Real World Usage Pattern (RWUP) and to create a stress life cycle block for simulation of accelerated testing, thereby optimizing the testing time and the development costs.