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This paper established a hardware-in-the-loop (HIL) system for developing the engine management system (EMS) of a motorcycle, which combines xPC target real-time simulator and PC based controller. An engine model of 125cc four-stroke gasoline engine that included the calculation of cylinder pressure is employed to be a control plant. A proposed control strategy developed with application of this HIL is verified to be superior to the conventional EMS of motorcycles. The proposed controller can send fuel injection and spark ignition control signals every two revolutions accurately via stroke identification method. During the engine running period, perhaps the ignition coil or other electronic equipment will conduct noise that interfere crankshaft tooth signal. Therefore, a Kalman filter is designed to improve the robustness of controller. Under interference, the performance of proposed controller is more satisfied than that without Kalman filter.