Abstract
Since 2009 the University of Idaho has developed a custom 250 cc engine for its Formula Hybrid vehicle program. This platform won the International SAE Formula Hybrid competition in 2014. In part this resulted from extensive hardware modifications, particularly the lubrication system, interface between stock components, and the manufacturing of a custom crank case. Equally important was extensive engine calibration and engine controller setup using a Motec M800. This thesis documents the rationale behind the various engine hardware modifications and outlines a simple calibration technique for spark timing and fuel injection timing as well as duration. Detailed information is given about Motec engine parameters for replicating stable, high performance operation of the custom 250cc engine across a broad range of load conditions. Future Formula Hybrid competition teams should find this to be a valuable source document and training document for powertrain development.