2015 USER MANUAL - Rev.01
Contents
1. 16 9 ENGINE PDC D 17 9 1 ENGINE OPERATING INSTRUCTIONS 17 9 2 OIL SPECIFICATION ie ek ees uu uuu Ud d VES M edd MD DE 18 9 3 ENGINE OPERATING BOUNDARIES 18 10 POWER TRAIN vetu doctas ved mn aa Lex cubat da ibo ene Gud Ui EC Debbie MV 20 10 1 GEARBOX Lo dics tee unu E ME MM n eee 20 10 1 1 GENERAL DETAILS ioi ie u uu uuu EENEG 20 10 1 2 RATIO CHARTS ioiii i aa ei a 20 10 1 3 DIFFERENTIAL SS u ea eee 20 1014 LUBRICATION u uuu n uu nupus upaku eat Pad eee bu is nu 21 10 1 5 MAINTENTANCE dus Eege ENN ENEE ENEE 21 10 10 DRAWINGS uu EER EE 21 10 2 FRONT DIFFERENTIAL uses uu u u u a a manuna N Ge ae ed ee ene 31 10 2 1 GENERAL DETAILS itv ew oa Wese ie we GN Gee Q 31 10 22 RATIO CHART diets Fo sen ER cee ea u ei 31 10 2 3 DIFFERENTIAL une eegene eegend 31 10 24 LUBRICATION 2 22 RE GE GES u NDA E Ee u GE N EE Ge GER GER 32 10 2 5 MAINTENANCE artsen ERG de SWOEG ee es de ein EE ee GE Ge GE Eeu Ee c 32 10 2 6 DRAWINGS iss ME EG ME RA AE GE ee Ge Ee Ge GM Ee UN waqa yas eN 32 10 3 REAR DISCONECT CLUTCH 36 10 31 GENERAL DETAILS uuu u ese ee Gee de ax Evita cas eue dure cR ee 36 10 3 2 TECHNICAL DETAILS uu uuu Ne Es Oe be Ge GP Ge se rate tei tu suan ei 36 10 3 3 EUBRIC2. od Rear and Front Driveshaft Completedriveshaft 4 1 CV joint Lil 2 Jet eem 1 1 J 3 Rubber 1 4 e331clamp 2 L5 IDiveshat 1l 6 M1050 Che bot AAN m 270 7 910 Nordlock washer el lI i comes TET OS 9 Rubber mounting plate 1 K 108 Lobr joint RN EEN 11 928 circlip 1 12 Grease 1 125 13 22x26 dowelpin Lil Page 29 41 SuperCar Lites User Manual 2015_04 Rev 01 Propshaft EE 4 207 NPPB bearn BESSE S esas TT Zeene Mi f 1916 ange o jy EE AE ig laste Al is i315 joint EEE Page 30 41 SuperCar Lites User Manual 2015_04 Rev 01 10 2 FRONT DIFFERENTIAL 10 2 1 GENERAL DETAILS The front differential is equipped with a self locking differential with friction discs and pressing plates with ramps Its weight is approximately 27 kg 10 2 2 RATIO CHART Ratio of bevel gear is 8x31 10 2 3 DIFFERENTIAL ZF type self locking differential with triple friction discs and pressing plates with ramps acting symmetrically or not for driving or braking condition Driving Ramp 297 9 Braking Ramp 90 Preload 7m DaN Note A fell of preload from approximately 15 after 60 kilometers running in will be note Note The cold measured preload workshop is approximately 15 higher than that measured hot Page 31 41 SuperCar Lites User Manual 2015 04
3. Loctite 577 m 1 5 daN m Loctite 2 O kel CR zl mi us O Q 6 2 2 5 daN m Loctite Item 1 2 3 4 5 6 7 8 9 10 13 15 16 18 19 21 24 26 o70x1 5O ring 1 Pin 1 1 1 1 2 8 Overload clutch piston 1 94x25 O ring J1 AXK 4565 bearing 2 2 Belleville washer 34 6x2 Omg Li Piston adjusting shim 1 7_ Adjusting shim 11 Thrustbearinghub In 9 AS4565washer 11 SB72 ring 41 61910bearing 1 Ed Intermediate thrust bushing 42 Page 37 41 SuperCar Lites User Manual 2015_04 Rev 01 Handbrake Page 38 41 SuperCar Lites User Manual 2015_04 Rev 01 j AI m e D Go gie u SdaN Handbreak support 5 6002 2RS bearing Complete handbreak M8x20 CHc bolt s M6x10 Hc bolt Anti rotation plug Balance bar axle Lever support Balance bar HF5C ball joint Ball joint spacer M8 Simmonds nut spring washer Spring bushing es 6 Ei 9 uu Lesch Lech Om cn E mim 18 20 Master cylinder 21 23 Master cylinder bolt 2 24 Master cylinder support 2 25 M6 Simmonds nut 3 26 Master cylinder i 27 Handbreekbushing il 28 Pressure stopping spacer 1 1 29 M10 Simmonds nut 2 577 577
4. 31 SPS washer x25 CHc bolt 2 5daN m 648 Page 33 41 SuperCar Lites User Manual 2015_04 Rev 01 Description 1 M8 Simmondsnut 3 M7x16 CHe bolt Machined M7x16 CHc bolt Right plate 7_ o130circlip INK110 30 bearing Complete 8x31 final drive M12x30 CHc bolt Final drive set up shim set 11 elleville washer B 2 Pressure plate Friction disc Le d dd Differential set plate 5 C Differential sun aear Short flange stud Planet gear axle 7 Differential nut _ k c 1 P ore disc t gear a In I C B 3 Ll Pr CI m 3 GdaN 27 Nutstopping washer 29 je125x2 5 Oing Li 30 Left plate Cd 31 Longflange M7x25 CHc bolt O Je B3 2 2daN m 2 2daM m Front Differential Page 34 41 SuperCar Lites User Manual 2015_04 Rev 01 Front Housing Page 35 41 SuperCar Lites User Manual 2015_04 Rev 01 Description Qty Torque M8 Simmonds mut 2 3 03527 ipseal 2 M7x18CHcbolt ERE Machined M7x16 CHc bolt 2 2daN m 5 J Rightpate amp 11 L6 lewes Oring Mr IE o o s NK s bua C T 10 Comp lete 8x31 final drive ES See slate 13 Gore ise _ s pla LEL a OMIM EL EC lange stud ETS _18 Planet gear axe at _19 Planetgear 4 j 29 Long flange stud LIL 21 Differ
5. Differential Hem Description 3 o42x62x7 lipseal 4 M10x20 CHc bolt 2 Glu ty Torque 2 51 5daN m rh SL 5daN m 32210 Timken bearing B Final drive set up shim set 612 Nord Lock washer M12x25 CHc bolt 10 14daN m 64 41 Friction disc 12 Core disc _13 Differential set plate Differential sun 17 Planet gear axle Machined Mi 0x30 CHc bolt 8 20 Belleville washer _ 21 Differential cap 1 Page 25 41 22 M8x16 CHo bolt 10 35daN m 648_ SuperCar Lites User Manual 2015 04 Rev 01 23 Right plate 1 T 2daN m SdaN m gt A Rear Housing Page 26 41 SuperCar Lites User Manual 2015_04 Rev 01 1 M10x125 Simmonds nut 2 Differential housing OE m c 1012x57 Din d 98x2 5 o ring ste od Drain 3 J seal ial are KE plug 3 Lk 4 am da 1842 lu 16 Sealwre Jil J Clutch Accessories M7x30 CHc bolt 1 2 5daN m M7x16 CHc bolt 2 5daN m 3 CP3859 1250 slave cylinder 1 X are 3 1 Page 27 41 SuperCar Lites User Manual 2015_04 Rev 01 Rear Drop Gear Description 40x55x8 lip seal Complete transfer 6 Drain plug seal Drain plua Ka D 2 2 19 Drop gear input shaft 1 Page 28 41 20 Drain plug 111 SuperCar Lites User Manual 2015_04 Rev 01
6. Page 22 41 SuperCar Lites User Manual 2015 04 Rev 01 Item Description Qtiy Torque Glu Complete 8x31 final 1 a Reverse gear pinion 1 L1 1 b final drive bearing 1 Le SPS 07 washer 6 d M7x40 CHo boit 6 3 2 daN m 648 _2_ Gear advance shim set 1 3 Gearsshimset 1 _4_ 1 gear inner ra e 1 5 K50x55x20 bearing 6 6 Ji geart0x38 7 Dogringhub 3 8 Poging 3 J 9 2 gear 13x36 Jij J 10 Gear inner race 2 11 3 gear 13x28 Jij J 12 MA gear 15x27 Jif 13 5 gear 19x29 Jif 14 e gear 18x24 Jij TI 15 e gear inner race 1 16 NU208 bearing Jif J _17 JSecondaryshaftnut 1 18 daN m 18 Nut stopping washer 1 19 035 circhip Jil Secondary Geartrain Page 23 41 SuperCar Lites User Manual 2015_04 Rev 01 41 M7x16 CHcbolt 2 22daNm _42 Selector closing plate EUR ES 43 pin 2 O 44 Selector washer A Selector axe A ask fea di Complete dual pin rock 47 a_ Pusher spring LI jb jei0x25 Oring 48 49 a16x24x7 lip seal 50 M8x25 CHe bol w e D a D i I3 I CO 247 3 5 daN m e20x2 5 dowel pin 16x2 O ring cC co a i 5A Complete fork M 56 16 circlip 1 Selector Page 24
7. Liters Drain Frequency After a 50km Each Meeting 75W140 running in Particular Precautions No additives should be added to the oil The resulting consequences are not in any circumstances covered by SADEV When topping up the rear differential oil do not mix any other oil with that already in the box Storage and Use Be particularly careful with any bottles which are open when used e Close the bottle again properly after use to prevent the introduction of water or dirt e Store bottles horizontally protected from severe weather e Do not store bottles close to a washing station e Do not decant the oil into larger containers 10 1 5 MAINTENTANCE Washing Under Pressure When the rear differential is removed seal all openings correctly to prevent the ingress of water into the rear differential Glued components Glue components and tightening torque are shown in the 3D exploded view WARNING Glue components have been chosen during test sessions Only Loctite brand components must be used Sadev can t ensure consequences of false glue component choice 10 1 6 DRAWINGS Page 21 41 SuperCar Lites User Manual 2015_04 Rev 01 Primary Geartrain 1 26x37x7 lipsea Ill 2 a34 Seeger RE 3 INK26 20 bearing 4 Input shaft ER ring 2 6 Input shaft hub En KS M8x20 Hc bolt 2n Ee SC inner race 15 NU207 bearing L d 16 n stl nut LE eim fi e 18 jen 0 143
8. Oil and Filter replace 500km FEAD belt replace on condition Air filter clean or replace on condition Water radiator and pipe work pressure test replace on condition Oil cooler and pipe work pressure test replace on condition Catalyst replace on condition Page 19 41 SuperCar Lites User Manual 2015 04 Rev 01 10 POWER TRAIN 10 1 GEARBOX 10 1 1 GENERAL DETAILS The Supercar Lites SL90 20 gearbox is composed of a 6 front speed reverse Its weight is approximately 72 kg without cable of reverse gear It is equipped with a self locking differential with friction discs and pressing plates with ramps The reverse gear unlocking cable the lubrication pump and its suction screen and the gearing potentiometer are also provided 10 1 2 RATIO CHARTS st 2d 3rd dth 5th 6th Primary 10 13 13 15 19 18 Shaft 4 Secondary 38 36 28 27 29 2 Shaft Primary X Ider _ Secondary 10 1 3 DIFFERENTIAL ZF type self locking differential with triple friction discs and pressing plates with ramps acting symmetrically or not for driving or braking condition driving ramp 45 braking ramp 90 Preload 6 m DaN Note A fell of preload from approximately 15 after 60 kilometers running in will be note Note The cold measured preload workshop is approximately 15 higher than that measured hot Page 20 41 SuperCar Lites User Manual 2015 04 Rev 01 10 1 4 LUBRICATION Oil Capacity 4
9. Rev 01 10 2 4 LUBRICATION Oil Capacity 0 7 Liter Drain Frequency After a 50km Each Meeting 75W140 running in Particular Precautions No additives should be added to the oil The resulting consequences are not covered by SADEV When topping up the front differential oil do not mix any other oil with that already in the box Storage and Use Be particularly careful with any bottles which are open when used e Close the bottle again properly after use to prevent the introduction of water or dirt e Store bottles horizontally protected from severe weather e Do not store bottles close to a washing station e Do not decant the oil into larger containers 10 2 5 MAINTENANCE Washing Under Pressure When the front differential is removed seal all openings correctly to prevent the ingress of water into the front differential Glued Components Glue components and tightening torque are shown in the 3D exploded view WARNING Glue components have been chosen during test sessions Only Loctite brand components must be used Sadev can t ensure consequences of false glue component choice 10 2 6 DRAWINGS Page 32 41 SuperCar Lites User Manual 2015_04 Rev 01 Front Input Shaft Item Description Gty Torque Glue 1 Flange bolt 1 12 5daN m 270 2 Flange boit washer 1 C J m NM 7 Gear shim set Complete 8x31 final drive Gear advance shim set Final drive bearing D
10. 41 SuperCar Lites User Manual 2015_04 Rev 01 Item Description Qty Torque Glue _1 Reverse mounting plate 1 2 Jot0lgtO pin 2 Reversegear 1 a HK 2030 bearing 1 648 4 Reverse gear axe Lil 5 Deflector EN 6 M6x12 CHe boit 2 15daN m 648 _7_ Reverse gear fork axle Jil 8 M4x12 CHc boit 2 9 lei washer pel I _10 Potentiometer TI _11 o12xi8x5lipsel 1 12 6301 bearing 1 n alpin Ja 648 Complete reverse gear fork a PAP 1215 P10 bushing b reverse selector pin __ 648 15 M8x25 CHc bolt 4 25 daN m 270 16 16006 bearing RR 17 Barrel nose TI 18 JM8x12 CZHc boit 1 577 _19 BS8 washer CUT _20 M6x20 CHc boit 1 1 8 daN m 243 _21 6003 bearing 1 _22 Rocker axe 1 _23 6002 bearing 1 24 15 circlip Cd TC 25 29x2 Oring Jil _26 Selector closing plate 1 _27 M5x16CHc bolt 5 J06daNml _ 28 M8x35CHc bolt 1 3 5 daN m 243 _29 Rocker o 1 30 Reverse gearunlockingcable 1 286x3 O ring CH _32 JM6x16 CHc bolt 6 15daNm 33 Selector spring 1 33 pring 34 Selector bushing 1 35 Selectorbolt 1 22daN m 243 36 934x3 Oring Jil _37 Selector closing bock 11 38 Powershftshimset 1 Powershift dT LT 40 M7x30 CHc bolt 1 22daNm J
11. ATION 52 222 u EE u Ge GE Ee GE uu u usss 36 by E E Su Le 36 11 BRAKES eseni a aAA 40 11 1 PRE BEDDING AT ALCON sees este ke kes ke Re E EER ERGE EER ERGE EER ERGE EE RE RE R EE RE Re RE RE RE 40 11 2 USE OF PRE BEDDED DISCS IN COMPETITION 40 11 3 RUNNING IN INSTRUCTIONS 41 11 4 WEAR ALLOWANCE AND MAINTENANCE 41 11 41 BRAKE DISCS u tuw animu qas nec 41 11 4 2 BRAKE PADS EE 41 Page 2 41 SuperCar Lites User Manual 2015_04 Rev 01 1 VIEWS OF SUPER CAR LITES NULS Ns ur ee Page 3 41 SuperCar Lites User Manual 2015 04 Rev 01 2 DIMENSIONS Overall Length 3 961 mm Overall Width 1 780 mm Front Axle Centerline 1 780 mm 3 BODY COLOR e Bonnet Front Body Main Body Rear Spoiler VW LB9A e Wishbones Pushrods Bellcranks Galvanized Coating Color Silver Gray e Rear Progressive Pushrod Cr3 Coating Color Yellow Page 4 41 SuperCar Lites User Manual 2015 04 Rev 01 4 CAPACITIES Fuel Engine Oil Gearbox Oil Coolant Distilled Water _ Brake Fluid DOTA Brake Fluid Clutch Fluid DOTA Brake Fluid Rear Disconnect 0 55 liter 75W140 Clutch Oil Front Differential Oil 0 7 liter 75W140 5 TECHNICAL SPECIFICATIONS Weight 1100 kg Front Suspension Push Rod Independent Double Wishbone OHLINS TTX Adjustable Rear Suspensi
12. Gear Lever Gear lever side __ _ _ Gear lever side 14 Reverse gear unlocked vera 1 Eg oer BHe bolt EN Page 39 41 SuperCar Lites User Manual 2015 04 Rev 01 11 BRAKES 11 1 PRE BEDDING AT ALCON Most discs and pads supplied by Alcon are pre bedded The purpose of pre bedding the disc is to deposit an even transfer layer of friction material on to the surface of the disc The secondary reason for prebedding the disc is to thermally condition the disc The objective of pre bedding the pad is to take the pad through a heat cycle during which the resins contained within the pad are cured additionally any high spots on the surface of the pad are removed After the discs have been pre bedded and allowed to cool the disc and pads can be bolted on to the car and should be ready for competition use providing that the discs and pads are run in correctly 11 2 USE OF PRE_BEDDED DISCS IN COMPETITION Care needs to be taken during running in to obtain the best performance and life from pre bedded discs and pads The running in of discs and pads on the car immediately prior to competition use ensures that the face of the disc and pad are mated removing any high spots Lightweight discs are particularly sensitive to potential problems during use failure to correctly run in the discs and pads can result in problems including Long pedal Poor feel and modulation Vibration Premature wear Disc cracki
13. SUPER CAR ES 2015 USER MANUAL Rev 01 Page 1 41 SuperCar Lites User Manual 2015_04 Rev 01 1 VIEWS OF SUPER CAR LITES eene 3 2 DIMENSIONS RA EA AE ED ER 4 3 BODY COLOR EE 4 4 ENEE 5 5 TECHNICAL SPECIFICATIONS 5 6 SETUP x 222 a 6 6 1 SETUP ADJUSTMENT pid Rusa Fen se Ns Eege 7 6 2 BELECRANK SEITINGS ii ou ee se Nee Oe 8 6 2 1 FRONT BELLCRANK SETTINGS 8 6 2 2 REAR BELLCRANK SETTINGS 9 6 3 ANTI ROLL BAR STIFFNESS SETTINGS 10 6 3 1 FRONT ANTI ROLL BAR STIFFNESS SETTINGS seee 10 6 3 2 REAR ANTI ROLL BAR STIFFNESS SETTINGS 11 6 4 SUSPENSION SETTINGS 12 6 4 1 DEFAULT SUSPENSION SETTINGS 13 7 DASHBOARD i tops RE EN N rivis bola dte Ge OE ed EG s DUE 14 7 1 DASHBOARD INDICATOR AREAS 14 7 2 DASHBOARD SENSOR OUTPUT SCREENS 15 8 EPAS ee umama am GE EG SE De Ge Vene dite 16 8 1 CALIBRATION OF COLUMN
14. al 2015 04 Rev 01 6 3 2 REAR ANTI ROLL BAR STIFFNESS SETTINGS There are 3 different stiffness settings for rear Anti Roll Bar e Soft Both Left amp Right Anti Roll Bar push rods on Position A e Intermediate Both Left amp Right Anti Roll Bar push rods on Pos B e Stiff Both Left amp Right Anti Roll Bar push rods on Position C Page 11 41 SuperCar Lites User Manual 2015 04 Rev 01 6 4 SUSPENSION SETTINGS Not to be adjusted High speed compression damping Low speed compression damping Rebound Set Up e Use a 3 mm allen key or tool e Turn the adjuster clockwise to fully closed position position zero 0 e Turn counter clockwise to set the adjuster to recommended number of clicks e If you want to change setting adjust in steps of 2 3 clicks at a time e Focus on the main adjuster Main adjuster has 5 40 clicks range Compression Set Up e Low speed compression is adjusted by using a 3mm allen key e High speed compression is adjusted with a 12 mm wrench Page 12 41 SuperCar Lites User Manual 2015_04 Rev 01 We recommend you to adjust low speed compression in steps of 2 3 clicks and high speed 3 5 clicks to fine tune the set up The low speed adjuster has approximately 40 clicks and high speed 50 clicks To reset compression e Turn the adjuster clockwise to fully closed position position zero 0 Then turn counter clock wise to open and count the clicks until you r
15. ank and set to the mid position on the sight gauge Additives such as water wetter can be used or antifreeze where allowed 80 20 mix With the ignition and fuel pumps on the static fuel pressure should be set to 4bar by adjusting the fuel pressure regulator The engine should be cranked on the starter motor with the ignition turned off to achieve oil pressure The cranking duration should be limited to 5 second duration If oil pressure is not achieved after 3 cranking events please contact Mountune before taking any other action If oil pressure is successfully achieved switch ignition on and start the engine Allow the engine to run until water temperature reaches 85C Check during this warm up running that the engine and its installation are free from leaks Oil level should be checked following this warm up run Complete installation lap where possible Check water temperature on track is within specified guidelines and adjust radiator blanks as required to achieve this If an engine failure occurs please contact Mountune Racing before taking any action so as to avoid the loss of any evidence which may help understand the failure Page 17 41 SuperCar Lites User Manual 2015_04 Rev 01 9 2 OIL SPECIFICATION A fully synthetic oil of viscosity range 5W50 or 10W60 should be used such as Shell Racing or Mobil 1 9 3 ENGINE OPERATING BOUNDARIES The following operating limits for the engine should be observed Eng
16. ce on brake discs should be considered as 1mm per face which sums up to 2 mm in total Note As a cautionary note it is not just the thickness of the disc that should be used to consider its suitability for continued use A brake disc which has been overheated can become distorted and or display other signs such as cracking both of which could give cause to replace the disc before its minimum thickness indicated above has been reached 11 4 2 BRAKE PADS PNR4441X702 4 brake pads should be replaced when they have Amm friction material remaining As a side note thickness of the pad is mm as 5mm backplate and 2mm friction material Page 41 41 SuperCar Lites User Manual 2015 04 Rev 01
17. each the recommended number of clicks See recommended Set up data in the Mounting Instructions for each shock absorber strut CAUTION Do not use force delicate sealing surfaces can be damaged Hand tighten only 6 4 1 DEFAULT SUSPENSION SETTINGS For Front and Rear Suspensions the default settings are as below GNE NN GN NE Page 13 41 SuperCar Lites User Manual 2015_04 Rev 01 7 DASHBOARD 7 1 DASHBOARD INDICATOR AREAS e RPM Indicator Corresponding LEDs light up at indicated engine rpm e Oil Pressure Displays the current oil pressure e Oil Pressure Alarm 3 LEDs light up if pressure is below 1 5 bar e Battery Voltage Displays the current battery voltage e Menu Selection Switches between sensor displays e Engine Coolant Temperature Displays the current coolant temperature e Engine Coolant Temperature Alarm 3 LEDs light up if temperature is above 100 C e EPAS Power Level Adjuster Adjusts the power level of EPAS CW softer CCW stiffer Page 14 41 SuperCar Lites User Manual 2015_04 Rev 01 7 2 DASHBOARD SENSOR OUTPUT SCREENS Screens can be switched by using menu selection buttons e Throttle Position Displays the current throttle position over 100 e Lambda Sensor Output Displays the current lambda sensor reading e Oil Temperature Displays the current oil temperature e Fuel Pressure Displays the current fuel pressure Page 15 41 SuperCar Lites User Ma
18. ential case Lil 2 30210 Timken bearing APE 25 Preloadshimset Jil ES EE IS Ah E washe EE EE 29 401 EA GEN vlae EE lc ie CHc bolt 6 22daN m 243 Machined M7x25 CHc bolt 2 22daNm 243 10 3 REAR DISCONECT CLUTCH 10 3 1 GENERAL DETAILS The rear disconnect clutch is to disconnect the rear differential when you use the hand break The weight is 7 5Kg 10 3 2 TECHNICAL DETAILS The rear disconnect is adjusted from Sadev on a hydraulic test bench The minimum pressure to disconnect the rear differential is 35 bars The Sadev handbrake is adjusted and tested on a bench See the drawing to know the connectors For this system the oil is dot4 or dextron WARNING Be careful when you purge the system If you don t make it correctly the system will not disconnect the rear differential when you will pull the handbrake 10 3 3 LUBRICATION Oil Capacity 0 55 Liters The disconnect is delivery from SADEV with oil inside Oil Viscosity 75W140 10 3 4 DRAWINGS Page 36 41 SuperCar Lites User Manual 2015 04 Rev 01 Torque Drain plug Drain plug seal 45x60x7 lip seal M8x16 BHc bolt Main housing Aluminium washer Dash03 fitting M10 bleeding bolt 61909 bearing 61811 bearing eload washer riction disc ore disc Venting fitting Spring Stud Thrust bushing KB 030 ARO bearing 24 Cylinder chamber Rear Differential Disconnector
19. ine speed Maximum 8000 rpm Engine speed 9000 rpm Advise engine is removed Water Temperature Maximum temperature 100 C Desired operating range 70 C 85 C Short excursions less than 90 seconds above this temperature during start line procedures will be accepted Oil temperature Maximum temperature 130 C Desired operating range 100 C 120 C Oil pressure Minimum pressure lt 2bar for duration of 2 5 seconds Desired operating range 4 5 bar Fuel pressure Minimum pressure 3bar Desired operating range 3 5 4 5bar If the above operating conditions are exceeded Mountune Racing will decide either to remove the engine or to continue to use the engine with a reduced life Page 18 41 SuperCar Lites User Manual 2015_04 Rev 01 Engine Management Safety Strategies Mountune Racing utilises a number of safety strategies within the engine management system to assist in protecting the engine from operation outside of the operating conditions These are as follows Engine Speed Engine rev limit set to 8000rpm Engine rev cut set to 8100 rpm Engine oil temp rev limit below 50C9 oil temp a reduced rev limit is engaged soft cut Engine coolant temp rev limit below 60C and above 110C water temp a reduced rev limit is engaged soft cut Pressure Protection Low oil pressure set to 3 bar rpm gt 1000 a complete engine cut is applied Service Intervals The following service intervals should be observed
20. ios are Motion Ratio Chassis Bellcrank Wheel Full Full Mounting Mounting Travel Rebound Compression Point Point Non Progressive Motion Progressive Motion B 4 240 052 083 B 5 210 058 1 00 B 6 180 66 1 25 Page 8 41 SuperCar Lites User Manual 2015_04 Rev 01 6 2 2 REAR BELLCRANK SETTINGS There are two operations modes for the rear suspension e A Pushrod Length I 300mm Non Progressive Motion Pushrod color Silver Gray code AV4015 e B Pushrod Length 2330mm Progressive Motion Pushrod color Yellow code AV4145 Both modes have three individual stiffness options providing different motion ratios accompanied with different wheel travel values Predifined rear bellcrank positions and their effects on suspension motion ratios are Motion Ratio Pushrod Bellcrank Wheel Full Full Length Mounting Travel Rebound Compression Point mm Non Progressive Motion A 300mm A 300mm A 300mm Progressive Motion B 330mm 0 77 B 330mm 0 90 B 330mm e 180 0 66 1 11 Page 9 41 SuperCar Lites User Manual 2015 04 Rev 01 6 3 ANTI ROLL BAR STIFFNESS SETTINGS 6 3 1 FRONT ANTI ROLL BAR STIFFNESS SETTINGS There are 2 different stiffness settings for front Anti Roll Bar e Soft Both Left amp Right Anti Roll Bar push rods on Position A e Stiff Both Left amp Right Anti Roll Bar push rods on Position B Page 10 41 SuperCar Lites User Manu
21. ng All discs can suffer from premature cracking this is normally caused by thermal shock occurring when the disc is either cooled or heated too quickly Additionally an excessive rate of disc temperature increase can result in failure of the heat to be absorbed into both braking faces and the vanes evenly Any significant temperature variation between the opposing flanges including the mounting flange can cause and promote disc coning and stresses within the disc cheeks normally leading the problems listed above Page 40 41 SuperCar Lites User Manual 2015_04 Rev 01 Heavier weight discs are more stable and less prone to these problems due to the increased structural rigidity gained from 48 and 72 vane design and generally increased flange thickness It is still advisable to run in the discs carefully as per instructions to follow To prevent these problems an appropriate and proven running in procedure needs to be followed during rallies races and tests We suggest that the following procedures are employed 11 3 RUNNING IN INSTRUCTIONS e 5 brake applies from slow speed and light pedal pressure to complete system check e 15 brake applies from 80 to 40 kph light to moderate pedal pressure 2 5 3 0 seconds line pressure 20 bar e 15 brake applies from 120 to 60kph light to moderate pedal pressure 4 0 seconds line pressure 20 bar 11 4 WEAR ALLOWANCE AND MAINTENANCE 11 4 1 BRAKE DISCS Wear allowan
22. nual 2015 04 Rev 01 8 EPAS The vehicle is equipped with an Electrical Power Assist System The user can adjust the level of assistance with the EPAS Power Level Adjuster next to the Dashboard pictured below CW softer CCW stiffer 8 1 CALIBRATION OF COLUMN It is normal for the steering wheel to move on initial power up and during calibration Do not attempt to hold the wheel at this time or the settings may become corrupted e Set Power Level Adjuster fully counter clockwise e Switch on Electronics 12v until LED next to the Power Level Adjuster lights up Immediately switch off and then back on until LED lights again e Continue to do this 3 more times until on the 4th time the LED lights and flashes this is the calibration phase e he LED will extinguish at the end of calibration when you can now use the system Calibration only needs to be carried out once at installation as the settings will be retained even when power is removed If any unexpected behavior is observed with the EPAS the owner shall contact the car manufacturer Page 16 41 SuperCar Lites User Manual 2015 04 Rev 01 9 ENGINE 9 1 ENGINE OPERATING INSTRUCTIONS The following should be carried out immediately prior to operating the engine The engine should be operated with Sunoco 260GT Plus fuel Agreement to use another other fuel should be made with Mountune prior to engine operation Water level should be checked in the header t
23. on Push Rod Independent Double Wishbone OHLINS TTX Adjustable Wheels Rims Motegi 17 X8 PCD4X108 ET60 Tires 215 40ZR17 Brakes ALCON 330mm ventilated brake discs with 4 piston brake calipers Page 5 41 SuperCar Lites User Manual 2015_04 Rev 01 6 SETUP Drive SL90 20 15 27 18 24 Front Rea N mm Adjustable Adjustable Stiffness Geometry Caster Camber Toe e Anti Dive 43 7 Anti Squat 23 Wheel Travel Camber Gain 0 0146 mm Tyres Circumference Page 6 41 SuperCar Lites User Manual 2015_04 Rev 01 6 1 SETUP ADJUSTMENT Adjustment Rear Camber Change wishbone turnbuckle turnbuckles Caster Change front 1 turn of front 0 85 turnbuckle contraction 1 turn of rear 0 85 turnbuckle extension Toe Change 1 turn of Rodend Page 7 41 SuperCar Lites User Manual 2015_04 Rev 01 6 2 BELLCRANK SETTINGS 6 2 1 FRONT BELLCRANK SETTINGS D 4 T cw gt 3 9 U VI Ce QT an We A N d 4 4 pal y yi f lt There are two operations modes for the front suspension e A Suspension Mounted to Point A Non Progressive Motion e B Suspension Mounted to Point B Progressive Motion Both modes have three individual stiffness options providing different motion ratios accompanied with different wheel travel values Predifined front bellcrank positions and their effects on suspension motion rat
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