Design and Validation of a Competition Grade Off-Road Motorcycle from a Stock Dual-Sport Baseline

Resumo

The aim of the study is to convert an existing production setup to dual-sport motorcycle into a competition-grade off-road prototype through systematic re-engineering of the chassis, suspension, and ergonomic layout. The primary objective is to enhance vehicle dynamics, handling precision, and rider control, while maintaining overall reliability and cost-effectiveness. The methodology combines analytical design, finite element simulations, fabrication, and field validation, focusing on critical parameters such as rake, trail, wheelbase, suspension travel, and weight distribution. Testing activities included geometry measurement, centre of gravity (CoG) analysis, suspension tuning, braking evaluation, and rider-based feedback assessments to verify the improvements achieved. The outcomes indicate notable gains in off-road performance including better traction, increased suspension compliance, greater ground clearance, and reduced overall mass. The study presents a structured and economic framework suitable for student-level prototype development and competition motorcycles, demonstrating the potential for performance enhancement from a production baseline.