Radical Performance Engines GSX-R Engine Operation Manual Version 4 - 18.12.14 Contents

Specifications ...... 1 Installation ...... 1 Re-Starting ...... 9 Rear Engine Brace ...... 1 Service Intervals ...... 9 Oil System...... 1 Engine Oil and ...... 9 Coolant System ...... 1 Oil Filter Fitting Procedure ...... 9 Fuel ...... 1 ...... 9 Octane Boosters ...... 1 ...... 9 RPE – Quaife Gear Drive System ...... 1 Engine Returns ...... 10 Types of Oil Systems ...... 1 Balancing Bodies on a 4 ...... 11 Oil Type Number 1 - Blanking Plates, No Jet...... 2 Life Racing ECU ...... 11 Oil System Number 2 - Oil cooler fittings and jet ...... 2 MBE ECU ...... 12 Oil System 3 – Oil Cooler Fittings and Bung ...... 3 Instructions For Retrieving Data from Life ECU and Data logger ...... 13 Oil System 1 Diagram - Cast Pan……………………………………………5 Driving Techniques for with an RPE Engine ...... 14 Oil System 1 Diagram - Billet Sump Pan…………………………………..………6 Contact Details ...... 15 Oil System 2 & 3 Diagram…………………………………..…………………………..7 Engine Management ...... 7 MBE - Radical Easimap Setup Screen ...... 7 Life Racing - PTMon ...... 7 Throttle and Airbox installation ...... 8 Airbox ...... 8 Fluid Levels and Temperatures ...... 8 Coolant Temperature ...... 8 Coolant Level ...... 8 Oil Temperature – both Wet and Systems ...... 8 Oil Level ...... 8 Dry Sump Oil Level ...... 8 Starting Procedure……………………………………………………………………………10

Installation Specifications The engine should be mounted into the chassis by means of four bolts into the mounting points on each side of the and two bars through the horizontal rear mountings in the above and below the gearbox through the rear engine Brace. See next Page for Rear Engine Brace fitting procedure.

Ensure no looms or hoses are trapped between the engine and chassis.

All sensors should be connected correctly and in working order, including:

• Air charge temperature • Position Sensor • Oil pressure • Fuel Pressure (if applicable) • GSX-R 1300S • GSX-R 1300T • Coolant temperature • • • Oil temperature Barometric sensor • Phase Sensor (if • GSX-R 1350T • GSX-R 1340T applicable)

• GSX-R 1400T • GSX-R 1500 The oil system must be connected as per the information in this operation manual. Please read this document carefully, there are different types of oil system fitted to RPE 4 cylinder engines. Please ensure the correct oil system • GSX-R 1550T • GSX-R 1585T is used. There is more information on the various oil systems on pages 2 to 7.

• GSX-R 1600T • GSX-R 1300 Turbo PLEASE BE AWARE THAT FITMENT OF AN INCORRECT OIL SYSTEM COULD CAUSE AN ENGINE FAILURE AND WILL • GSX-R 1615T • GSX-R SS 1500 INVALIDATE YOUR ENGINE WARRANTY.

Rated Speed –10,500 rpm The coolant system must be connected and capable of providing adequate cooling to maintain the correct operating temperatures outlined later in this – 1, 2, 4, 3. document.

Cylinder 1 is on the left hand side of the engine (Generator side). Please contact RPE if you have any questions concerning the installation of your engine. Contact details are listed on page 16. 1

REAR ENGINE BRACE

Dear Radical owner, mechanic or ,

Your engine has been returned with a supporting brace on the rear of the engine:

In order to fit your engine you will need to modify the rear engine cradle by removing a boss as shown:

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Fluids Oil Systems Variations Oil System Recommended – Silkolene PRO R or PRO 4 15W-50 Due to a number of different oil cooling systems in circulation, the oiling system must be confirmed before the engine is installed. PRO R/4 is a unique, fully synthetic lubricant for ultimate engine protection and superior clutch and gearbox operation for high performance 4 Oil System Number 1: 2 blanking plates installed on the engine oil cooler inlet engines. and outlet ports and the oil jet behind the oil filter is removed. If this specific oil is not available to you, please use a comparable oil. Oil System Number 2: -8 or -10 oil cooler fittings on the engine oil cooler inlet and outlet ports, and the oil jet behind the oil filter has a 3mm hole drilled in NEVER USE ENGINE OIL IN A MOTORCYCLE ENGINE. THE INTEGRAL it. GEARBOX WITHIN THE MOTORCYCLE ENGINE WILL SHEAR THE MOLECULES IN THE OIL. ALSO, MOTORCYCLE ENGINES HAVE INTEGRAL WET CLUTCHES. Oil System Number 3: -8 or -10 oil cooler fittings on the engine oil cooler inlet and outlet port. A blanking bung is installed behind the oil filter, in place of Coolant System the oil jet.

50% water and 50% /summer coolant. • On later model engines, that are fitted with a cast type sump pan, Fuel there is only one type of oil system regardless of installation. One blanking plate on the oil cooler inlet port and the oil jet behind the oil RPE Suzuki engines should be run on a minimum of Super Unleaded 98 RON, filter is removed. or 100 octane race fuel.

• If you are unsure as to the specification of your previous engine, RPE Tuned engines in the USA should be run on racing fuel such as Cam2 or a can provide you with the necessary information. minimum of 108 Octane.

Octane Boosters • An RPE technician can also confirm the specification for you if an engine exchange is to take place at a race meeting. If fuel of the correct octane level is not available then octane boosters can be used, please contact RPE before using octane boosters in fuel. • If in any doubt please Phone or Email

RPE – Quaife Gear Drive System Tel +44 (0)1733 331919 Recommended Oil – Shell Helix Racing Gear Oil 75W-90 Email [email protected] or Shell Helix Racing Gear Oil 75W-90 is a synthetic gear oil designed to provide optimum protection under extreme load conditions, whilst maintaining high [email protected] efficiency.

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Oil Type Number 1 - Blanking Plates, No Jet Billet Sump

This type of oil system can be used with both RPE cast (Silver) and billet (Gold) dry sump pans.

The restrictor jet behind the oil filter is also removed. The oil return pipe Jet Location from the scavenge pump goes through the oil cooler (or water to oil heat exchanger) before returning to the oil tank.

Cast Sump

Jet Location

Blanking plates are fitted to the engine’s OEM oil cooler in and outlet ports.

IMPORTANT When this oiling system is used, the jet behind the filter must be removed.

If the engine is fitted with a cast sump pan, there will be no blanking plate on the sump pan, just one on the engine. IF THIS IS NOT DONE IT WILL RESULT IN ENGINE FAILURE.

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Oil System Number 2 - Oil cooler fittings and jet Oil System 3 – Oil Cooler Fittings and Bung

This system can only be used with RPE billet dry sump pans. This system is mainly used on the Radical SR4, as they have long hoses that run to and from the oil cooler due to the radiator being mounted further away from the engine than normal

Jet with 3mm diameter hole Blanking Bung

There are two fittings on the engine oil cooler inlet and outlet ports, they are There are two fittings on the engine oil cooler inlet and outlet ports, they are either -8 or -10. In this case there is a restrictor jet with a 3mm hole located either -8 or -10. In this case there is a blanking bung behind the oil filter. The behind the oil filter. The oil returning from the scavenge pump is pumped oil returning from the scavenge pump is pumped directly back to the oil tank. directly back to the oil tank.

IMPORTANT IMPORTANT When using this oiling system, the jet behind the filter must have a hole When using this oiling system, the jet behind the filter has no hole drilled, it drilled in it. is a solid bung.

IF THIS IS NOT DONE IT CAN RESULT IN ENGINE FAILURE. IF THIS IS NOT DONE IT CAN RESULT IN ENGINE FAILURE.

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To dry sump tank Oil System 1 Diagram – Cast Sump Pan

Radical Performance Engines GSX-R Oil System – 2008 Onwards

This is for an RPE Hayabusa Engine with a cast sump pan.

Breather Pot Connection

FROM UNION ON TOP OF ENGINES BREATHER POT

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Oil System 1 Diagram – Billet Sump Pan

To dry sump tank

Radical Performance Engines GSX-R Oil System Breather Pot Connections This is for an RPE Hayabusa Engine with a billet sump pan.

FROM UNION ON TOP OF ENGINE BREATHER POT

FROM UNION ON TOP OF ENGINES BREATHER POT

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To engine breather tank

Oil System 2 & 3

Radical Performance Engines GSX-R Oil System Pre– Pre 2008 2008

This is for an RPE Hayabusa engine with a billet sump pan. This is for an RPE Hayabusa Engine with a billet sump pan.

To dry sump tank

Breather Pot Connections

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Engine Management Life Racing - PTMon Most RPE engines will either use MBE or Life Racing engine management. The pictures below show the monitoring programs which should be loaded on a laptop that is connected to the ECU each time the engine is started.

MBE - Radical Easimap Setup Screen

6 7

1 2 3

0.19 8 9 10 11 12

1) Engine coolant temperature (ect1) – changes from red to green when in correct range of 60 oC to 95 oC 4 5 6 7 8 2) Engine oil temperature (eot) – changes from red to green when in correct range of 50 oC to 120 oC 3) Engine oil pressure (eop1) – At idle, 70 psi when cold /20 psi when hot 4) Engine rpm (rpm) – Engine should idle between 1500 and 1800rpm 1) Engine RPM – (Engine should idle between 1500 and 1800rpm) 5) Throttle position sensor (tps1) – needs to be set to 4% at idle 2) Throttle Position Sensor – (set at 0.18V at idle) 6) Engine sync state – should be at 720 when engine is running, turns green 3) Barometric pressure when correct 4) Coolant Temperature 7) Fuel pressure (fp1) – changes from red to green when in correct range of 5) Oil Pressure 2.8 bar to 3.2 bar 6) Oil Temperature (Minimum of 45°C, Maximum 120°C) 8) Battery voltage (vbat) – above 12.5 volts when engine is running 7) Battery Voltage 9) Air charge temperature sensor (act1) – air inlet temperature 8) Air Inlet Temperature 10) Engine ECU temperature (btMax) – temperature of the engine ECU 11) Baro sensor pressure (bap) – below 1030 mBar

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12) Gear Indicator – Should be Neutral when starting. Gear position voltage The sump is baffled and the oil takes some time to settle. displayed for technical use Dry Sump Oil Level Throttle and Airbox installation For cars fitted with a dry sump system the oil level must be checked using the dip stick supplied. The dry sump oil tank level must be maintained at the TOP Airbox mark on the dipstick with the engine as close as possible to the Ensure that all fixings on the air box are tight and there are no foreign bodies recommended on track running temperatures (See Fluid Levels and that could fall into the engine and cause damage once the engine has been Temperatures opposite). The bottom mark is only used when the oil is cold. started. All bolts/screws in the airbox must be lock wired or fixed using The level should be checked AFTER running the engine up to temperature thread lock. and after holding the revs at 4,000rpm for ten seconds, to allow the oil to be scavenged back to the oil tank. The engine should be turned off to check the Fluid Levels and Temperatures level. (The sight glass in the side of the engine should be ignored).

Coolant Temperature When the engine is on track, the coolant temperature should be between 70°C and 90°C.

Coolant Level When the system is fully bled, the coolant should be full to the top of the swirl pot, and there should be a minimum of 10 to 20mm in the coolant catch pot.

Oil Temperature – both Wet and Dry Sump Systems When the engine is on track, the oil temperature should be between 90°C and 115°C. Dipstick being used to check oil level in a Radical SR3 Wet Sump Oil Level The procedure for checking the oil level is as follows. This should be done with the car on level ground. If you do not have the correct dipstick for checking your dry sump tank, contact a member of the Radical Parts Department immediately. Their With the engine running and the coolant up to 50°C, hold the revs at 3000 contact details are on page 16. rpm. There should be no bubbles in the sight glass, from 3000RPM, blip the throttle and an air bubble should appear in the sight glass.

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Starting Procedure a. Always start the engine with a laptop connected to the ECU so that all Service Intervals engine parameters can be monitored during warm-up. This also confirms all the vital engine sensors are working. Engine Oil and Oil Filter b. Check plenty of oil is visible in the oil tank and the coolant level is to the The engine oil and filter should be changed after every 5 hours of running. top of the swirl pot. Oil Filter Fitting Procedure c. The engine should be dry cranked, some oil will have drained back into the 1) Apply a thin film of engine oil to engine if it has been previously run. This will return to the tank once the the sealing o-ring on the oil filter. engine is started. To dry crank the engine, disconnect the ignition coils and turn the engine over until it produces oil pressure and oil is returning to the 2) Screw the filter on to the engine oil tank. by hand, until the o ring on the oil d. Once the engine is producing oil pressure and the oil is returning to the filter contacts the engines surface. tank, re-connect the ignition coils and turn the ignition on. Start the engine with no throttle, then increase the engine speed to approximately 2,000rpm 3) Using an oil filter tool (shown in – 3,000rpm. Check the oil pressure - it should be a minimum of 60 psi. picture), turn the filter another 2 turns. e. When the engine coolant temperature reaches 50°C, hold the engine revs 4) To prevent the oil filter coming loose at 4,000rpm for a few seconds (this allows the scavenge system to clear oil during operation, a jubilee clip must be from the crankcases) and turn the engine off. fitted around the oil filter. The adjuster screw housing of the jubilee clip should sit WARNING – RADIATOR COOLING FANS ARE NOT FITTED AS STANDARD. DO against the bolt in the crankcases, as NOT LET THE WATER TEMPERATURE EXCEED 90°C WHEN WARMING THE shown in the picture. It should be located ENGINE TO CHECK THE OIL LEVEL. hard up against the right hand side of the f. Immediately check the oil level, it must be between the top two marks on bolt, as you look directly at the oil filter. If it is on the wrong side, it will not the dipstick. effectively prevent the oil filter from coming loose.

Re-Starting Fuel Filter a. Ideally, the engine should be started 45 minutes prior to going on track. The fuel filter should be cleaned after every 20 hours of running or visually Turn the engine off when the coolant temperature reaches 85°C and allow inspected - especially if you have recently fitted a new , are heat to soak into the engine. Restart 10 minutes before going on track and experiencing fuel starvation, or a drop in fuel pressure. get the coolant temperature to 75°C. b. The oil level should be checked after every hour of running, and it should Air Filter be topped up to the level indicated in these instructions. The engines air filter should be inspected before every race. It should then be cleaned and oiled as per the manufacturer’s instructions and should be replaced as required. 9

Engine Returns To keep within the warranty rules, the ECU should always be returned to RPE with the engine. This is for two reasons: When returning an engine to RPE for a refresh or repair, the engine should be removed from the vehicle and be externally clean. Please follow the • Data can be checked. procedure below. • Engine hours can be reset on the ECU.

• Flat packed metal crates can be collected from your local distributor, In the event of an engine failure: alternatively you can drop off your engine at your distributor and • RPE should be contacted and the ECU’s data should be downloaded they will process the engine on your behalf. and e-mailed to Radical Performance Engines technical: ……………….. ([email protected]). • All engines must be drained of fuel, coolant and oil. • Debris may have transferred to the oil lines and cooler. An exchange • Tilt the engine, so that the drain bung on the sump is the lowest oil cooler MUST be fitted and the oil lines flushed thoroughly with point of the engine and leave for 3 to 5 hours. non-water based cleaner (Such as Petrol or Jizer cleaning fluid). The cooler can be purchased either from Radical Performance Engines or • Bung all oil, water and fuel inlets and outlets. your local Radical distributor. If in good condition, you will only be charged the cost for ultrasonically cleaning your exchange oil cooler. • If possible shrink wrap or seal the bottom end of the engine to catch any residual fluids. Failure to carry out the above will result in your engine warranty being void and no claim can be made against it. • Ensure no previous shipping details remain on the shipping container as this may cause delays with shipping and customs. As soon as your original engine is repaired and fully refreshed you will be credited/invoiced for the work/parts required.

• Locate the engine securely in a crate. RPE do not cover the cost of removal and refitting of the engine, any third

party costs or replacement of fluids. • Add packaging to secure the engine.

RPE also offer a range of optional services when having your engine rebuilt. • Additional items (ECU, throttle bodies etc) must be packaged and These are: secured. • Injector testing and cleaning

• Heat exchanger strip and clean • Secure lid and affix address labels to lid and side of crate (minimum • Oil cooler ultrasonic cleaning of 2 labels)

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Balancing Throttle Bodies on a 4 cylinder 6) Place the syncrometer in throttle body number 3. This body is not adjustable it is your base which the rest of the bodies need to match. The Life Racing ECU syncrometer will normally read between 5 and 7.

1) Connect a laptop to the car and load PTMon. (This displays the engine sensor readings) 1 2) To achieve a base setting the throttle needs to be fully closed. To ensure it 4 is, wind the idle adjuster screw out whilst watching the TPS reading displayed in PTMon. The value should reduce as you wind the screw out. Once the value stops reducing, the throttle is fully closed.

2 3 7) Place the syncrometer in the other bodies, using a 7mm spanner and 2mm TPS Idle adjuster allen key (as shown in the picture below) adjust the other bodies to match screw the reading from body number 3. Please note that turning the adjuster clockwise opens the body. To adjust, loosen the 7mm nut and turn the adjuster in the centre. Once the reading is correct, lock off the adjuster by

tightening the 7mm nut and holding onto the 2mm allen key to stop it from 3) Set the TPS value to 2.0. To do this, loosen the TPS using a 3mm allen key, as moving. When balancing match the reading on cylinder 3 and 4 with the shown in the picture. Once loose, turn the TPS until its value shown on adjuster, then match 1 and 2 finally use the centre adjuster to match both PTMon is 2.0, and re-tighten the securing screws. sides.

TPS Adjuster Screws

4) Using a 3mm allen key turn the idle adjuster screw, until the TPS value is 4.0. 8) Once all four bodies give the same reading on the syncrometer, the bodies 5) Now you are ready to start the engine. Check the engine oil, water and are balanced. Give the engine a couple of small blips and check the TPS electrical connections. (Especially if it is a new engine installation). Once you value returns to 4 and all the throttle bodies read the same on the have confirmed these are OK, start the engine and let it idle. Make sure the syncrometer. engine temperature is maintained within its operating parameters. Do not allow the water temperature to rise above 90°C.

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MBE ECU 6) Place the syncrometer in throttle body number 3. This body is not 1) Connect a laptop to the car and load Easimap. (This displays the engine adjustable it is your base which the rest of the bodies need to match. The sensor readings) syncrometer will normally read between 5 and 7. 2) To achieve a base setting the throttle needs to be fully closed. To ensure it is, wind the idle adjuster screw out while watching the TPS reading displayed in Easimap. The value should reduce as you wind the screw out. 1 Once the value stops reducing, the throttle is fully closed. 4 TPS

Idle adjuster 2 0.19 3 screw 7) Place the syncrometer in the other bodies, using a 7mm spanner and 2mm allen key (as shown in the picture below) adjust the other bodies to match the reading from body number 3. Please note that turning the adjuster clockwise opens the body. To adjust, loosen the 7mm nut and turn the adjuster in the centre. Once the reading is correct, lock off the adjuster by tightening the 7mm nut and holding onto the 2mm allen key to stop it 3) Set the TPS value to 0.13. To do this, loosen the TPS using a 3mm allen key, from moving. When balancing match the reading on cylinder 3 and 4 with as shown in the picture. Once loose, turn the TPS until its value shown on the adjuster, then match 1 and 2 finally use the centre adjuster to match Easimap is 0.13, and re-tighten the securing screws both sides.

TPS Adjuster Screws

4) Using a 3mm allen key turn the idle screw up until the TPS value is 0.19 to 0.20. 8) Once all four bodies give the same reading on the syncrometer, the bodies 5) Now you are ready to start the engine. Check the engines oil, water and are balanced. Give the engine a couple of small blips and check the TPS electrical connections. (Especially if it is a new engine installation). Once value returns to 0.19 to 0.20 and all the throttle bodies read the same on you have confirmed these are OK, start the engine and let it idle. Make the syncrometer. sure the engine temperature is maintained within its operating parameters. Do not allow the water temperature to rise above 90°C.

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Instructions For Retrieving Data from Life ECU and Data logger If on the other hand this has been set up the next part will be in the drop down box I.e. Track maps & Data, SR3 or SR5 or SR8, customer name, track & 1. Connect a computer to the ECU/car and turn both the ignition and master date. switches on to power up the ECU. All you then need to do is select the appropriate item until it is complete. 2. A working directory now needs to be created. This selects the folder in which the data will be stored once it has been downloaded, and sets a route 6. Highlight “select” & press return. to find the information. It contains the name of the driver and/or car number etc. For example C:\Program Files\Life Racing\Track Maps & Data\SR3 (SR5, 7. A box comes up with “there is no LR directories config file at: - Create one SR8)\Customer\ Track & Date. – select Yes.

3. Open the Life Data icon on your desktop. 8. Another box with “place shortcut on desktop” select No.

4. Select F for file, then W for working directory. 9. Then select D for device and R for read data.

5. At the top of the screen, below the toolbar will be C:\Program Files\Life 10. In the next box select ok. If this data needs to be looked at, load up Life Racing\Track maps & Data. If not, correct this part by selecting the full stop View, click on File, Load and then find as above the appropriate file. Once you button… it goes back one section. Then by selecting “create”, a box comes up have loaded up a data file, the channels will be listed down the right hand with “enter new directory name”. Enter the appropriate information, such as side of the screen, to display a channel highlight it using the arrows on the car type, chassis number, circuit and date. Once this is done, press Enter. keyboard and press enter.

If the data needs to be e-mailed go through My computer, Program Files, Life Racing, Track maps & Data, sr3/sr5/sr8, customer, track & date select file or files to be e-mailed.

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Driving Techniques for Cars with an RPE Engine

Paddle shift cars: Cars on stick shift:

• The clutch is sharp, and needs to be let out slowly whilst the car is • All of the above applies, apart from the gear change technique. stationary. • To change up and down the gears at low revs the clutch must be used. • To pull away, engage 1st gear, with the clutch fully depressed, raise the • To change up the gears at racing pace, use of the clutch is not necessary, revs to 2500 rpm, and slowly release the clutch. but can be used if preferred. To change up the gears, you need to lift off • When the car is moving slowly, it is advisable to use the clutch on the the throttle, and pull back on the gearstick to engage the next gear. You way up and down the gearbox, and when changing up and down from 1st can then let go of the gearstick and it will return back to its central to 2nd at speed. However whilst on track, at racing speed the clutch is not position needed, and you can keep the throttle open on up changes. • Optimum revs to change up gears are between 9,500 and 10,000 rpm, as To change down the gears whilst applying the brakes, you need to depress this is where the engine reaches its peak performance. the clutch and push the gearstick forwards to engage a lower gear. As the • To change down you should wait until the revs have dropped to around gear is engaged you can release the clutch and let go of the gearstick, which 7,000rpm. will return to its central position. To come down multiple gears just repeat • The slick tyres on the car, the brakes and the engine will take a few laps this process, making sure the clutch is depressed for each down change. to warm up. Grip is greatly reduced on cold tyres, so it is important to take this into consideration, and slowly build up your pace. • The cars are at their best when driven smoothly, so gradual application of Should the car spin throttle, brakes and steering is best. Due to the design of a motorcycle engine, if it is forced to turn over • Throttle and brakes must be applied separately, never together. backwards the system can become damaged. It is important therefore • All braking, wherever possible, should be done in a straight line along that if the car is in a spin situation, the clutch is depressed as a matter of with down changes. If excessive brake pressure is applied whilst urgency, to reduce the risk of damaging the engine starter system. increasing steering lock this will unsettle the car and possibly cause the car to spin. • The car should be in a straight as possible position before the throttle is applied, with minimal steering lock on. If excessive steering lock is on whilst applying throttle, this will unsettle the car and possibly cause the car to spin. • It is important not to change gear while experiencing wheel spin, especially in the lower gears. 14

Contact Details

Radical Performance Engines Ltd Unit 24 Ivatt Way Westwood Peterborough PE3 7PG Radical Sportscars Tel (office): +44 (0) 1733 331919 Unit 24 Ivatt Way Tel (technical support): +44 (0) 7795490850 Westwood Fax: +44 (0) 1733 333666 Peterborough PE3 7PG E-mail Tel (office and parts): +44 (0) 1733 331616 Engine Rebuilds [email protected] E-mail RPE Technical Support technical1@ radicalperformanceengines.com Radical Technical Support technical2@ radicalperformanceengines.com [email protected]

RPE Parts Department Radical Parts parts@ radicalperformanceengines.com [email protected]

RPE Sales sales@ radicalperformanceengines.com 15