RX7 Competition Manual

Transcription

A-PDF MERGER DEMO
MAZDARX-7
COMPETITIONPREPARATION
ANDSERVICEMANUAL
@ Copyright1980byToyoKogyoCo.,Ltd.
CONTENTS
ENGINE
BasicSpecifications
l . E x p l a n a t i oann d D e s c r i P t i oonf
CompetitionParts
d arts
l l . A d d i t i o n aRl e q u i r e P
n perations
a n d F a b r i c a t i oO
lll. Machining
Procedures
and
lV. Checksand Measurements
V. AssemblyOperations
Vl. Checksand Adjustments
Vll. OperatingProcedures
cHASSTS
DRIVELINE
CompetitionParts
a n dA s s e m b l y
l l . N o t e so n M a c h i n i n g
and Practices
Adjustments
lll. Checks,
BRAKESYSTEM
Specifications
of
and DescriPtion
l. Explanation
CompetitionParts
ll. MachiningOPerations
l l l . C h e c k sA, d j u s t m e n tasn d M a i n t e n a n c e
ANDSUSPENSION
STEERING
Specifications
CompetitionParts
n perations
a n d I n s t a l l a t i oO
ll. Machining
' l l l . C h e c k sA, d j u s t m e n tasn d M a i n t e n a n c e
APPENDIX
, X - 7a n d RX-3
C o m p a r i s oonf S p e c iifc a t i o n sR
5
B
8
13
21
21
24
27
28
31
35
36
37
39
40
44
47
PREFACE
for your inter estin and e ffor ts
T o y o Ko g yoC o .,L td .,w i sh e sto extendappr eciation
This M anualr eflectsthe know l edge
w i t h t h e Ma zd aR X .7i n a u to mobilecompetition.
dev el s oughmuchr esear ch,
g a i n e db y Ma zd aco mp e ti to rs
a n d ToyoKogyoengineer thr
pr actic e.l t i s
and is to be consider edr ecomm ended
o p m e n tan d a ctu a lco mp e ti ti o n,
and m aintenanc e
i n t e n d e dfo r u se o n l y b y th o seser iouslyengagedin the constr uction
outlinedwithi nthe
and specifications
; e p ar ts,pr ocedur es
o f t h e R X-7i n co mp e ti ti o nth
M a n u a lare fo r ra ci n ga n d co mpetitionuse only,and specificallyhaveno r elatio nto or
lf the infor m aautomobiles.
o r o th e rp u rp o sefo r s tr eetand highway- dr iven
a p p l i c a ti o n
RX' 7,the res ul ts
t i o n c o n ta i n e di n th i s Ma n u a li s appliedto a str eetor highway- dr iven
ec onom y
and lossesin per for mance,
reducedr eliability,
m a y i n c l u d evo i d e dw a rra n ti e s,
a n d e m i s s i o n sa, l l o r s o m e o f w h i c h m a y b e i l l e g a li n c e r t a i na r e a sa n d w h i c h a r e
d y T o yoK ogyoCo.,Ltd.
d e fi n i t e lyn o t a p p ro ve b
W i t h t he p a rts,p ro ce d u re sa nd specificationsin the Manualthe competitor.c an
a s s e m b l ea n d ma i n ta i nth e e n g i ne,dr ivetr ainand chassiscomponentsand the v ar i ous
com peti tor
Theindividual
M azdaRX- 7.
i n vo l ve d
in a com petition
su b syste ms
a p p r o p r i a te
may not
pr
ocedur
es
in
M
anual
par
ts
this
outlined
o
f
th
e
and
ma
n
y
th
a
t
b
e
a
w
a
re
should
a nd
or
ganizations
, it is
com
petition
of
cer
tain
re
gulations
ru
l
e
s
a
n
d
th
e
u
n
d
e
r
b e a l l o we d
per
son
associat
edw i th
other
or
m
echanic
r
acer
,
o
f
th
e
co
mp
etito(
,
r
e
s
p
o
n
si
b
i
l
i
ty
the
per
tinent
of
r
egulation
s hi s
r
ules
and
of
the
h
a
ve
fu
l
l
u
n
der
standing
a
M
a
zd
a
to
r a c i n ga
is
no
ther
e
sec
ti
oni n
notice
r
eader
will
the
g
o
ve
rn
i
n
g
instance,
F
o
r
b
o
d
y.
c o m p - e ti ti o n
and
these
deta
i
l
s
as
r
oll
cage
str
uctur
e,
of
a
constr
uction
a
n
d
th
e
d
e
si
g
n
t h i s M a n u a ol n
izat
ions.
ion
i
ng
or
gan
fe
re
n
t
sanct
va
ry
w
i
th
d
i
f
i
r e q ur e m e n ts
and the r eaderis assu m edto
n e rei s a h i g hdegr eeof exper im entation,
I n c o mp e ti ti o th
individual
basis,is not cover edb y thi s
is
on
an
e
xp
e
ri
mentation
su
ch
th
a
t
understand
its affiliates,is the r efor e
p
o
si
ti
o
n
Ltd.,
and
Co.,
Kogyo
of
Toyo
fro
m
th
e
a
n
d
Manual,
pr
actice.
Co.,
Ltd. is inter estedi n the
Kogyo
Toyo
n
o
n
-re
co
mme
nded
a
s
c a t e g o r i ze d
but specificallycannot
exper
ience,
or
e
xper
imentation
co
mp
e
ti
ti
o
n
of
resufts any
p
ro
ce
d
u
re
analysisby appropr i ate
a
thor
ough
it
has
under
gone
u
n
til
n
e
w
a
r e c o m me n d
f
.
sta
f
e
n
g
i
n
e
e
ri
n
g
c o m p a ny
I n a n y fo rm o f a u to mo b i l eco mpetitionthe individualis also consider edto a s s um e
fo r h i s o r h e r a cti ons,and to r ealizeand acceptthat automobilec om pe'
r e s p o n si b i l i ty
activitywith a high degr eeof r isk of damageto
, h a zar dous
t i t i o ni s , b y i ts ve ryn a tu re a
e q u i p m e na[ n d / o rp e r s o n ailn j u r y .B y t h e a p p l i c a t i o on f t h i s M a n u a li t i s a s s u m e dt h e
i n b i v i d uawl i l l b e o p e ra ti n ga co mpetitionautom obileat or nearthe outer lim its of i ts
p e r f o r ma n ce
e n ve l o p ea, n d th e c loserto thoselimitsthe gr eaterthe r isk.NeitherT oy o
i n any
assum eanyr esponsibili ty
L
td
.,n o r a n yo f th e i raffiliatesor em ployees
C
o
.,
Kogyo
r equipmentor per sons,r esultingfr om the use of any
m a n n e rf o r a n y l o sse s,e i th reto
or s pec i '
of any par ts,pr ocedur es
M a z d aa uto mo b i l eisn co mp e ti tionor the application
M
a
n
u
a
l
.
i
n
t
h
i
s
o
u
t
l
i
n
e
d
fi c a t i o n s
ec tto
,
co mp e ti ti onis a constantlychangingar eaof endeavorsubj
F i n a l l y,a u to mo b i l e
pr
actice
is
but
r
ecomm
ended
best
is
the
cur
r
ent
Ma
n
ual
th
i
s
a
n
d
n e w t e i hn o l o g y,
time.
n
cti
ce,
at
any
w
i
th
o
u
t
t
o
ch
a
n
g
e
,
subjec
com petitiona,ndw e
A g a i n th
, a n kyo ufo r yo u ri n te restin the MazdaRX- 7in autom obile
your
in
effor
ts.
g
o
o
d
y
o
u
w
i
shes
l
u
ck
a
n
d
b
e
st
extend
ENGINE
ENGINE
BasicSpecifications
Type
12ARotary
per
rotor
Displacement,
573cc
Displacement,
total
11 4 6c c
ratio
Compression
lntakeporting
Exhaustporting
9.4:1
Carburetion
Twinthroat,downdraft
Weber
Lubrication
Wetsump
Peripheral
They differ from the stock housi n g si n t h e s ew a y s :
(1) The intake ports are filled in
solid.
(2) The intermediate
housinghas
an oil separatortank. :
(3) Thepassagesfor the oil pump
o n t h ef r o n th o u s i n ga r el a r g e r
passages.
Peripheral
Cooling
Liquid
lgnition
Transistorized,
capacitive
discharge
(cDr)
M a x i m u ma l l o w a b l e
e n g i n es p e e d
9.000RPM
Explanationand Description of
CompetitionParts.
A. Housinggroup.
1 . R o t o rh o u s i n g4, 3 5 21 0 ' 1 0 0
I t h a s t h e f o l l o w i n gd i f f e r e n c e s
f r o mt h es t o c kh o u s i n g :
( 1 ) T h ei n t a k ep o r t i n gi s p e r i p h e r al.
(2) lt is sandcast from lowervolumepatterns.
(3) The coolantpassagesare different.
(4) Thetrochoidsurfaceis directly chromeplatedonto the casti n g i n s t e a do f b e i n ga s h e e t
metalinsert.
3 . T e n s i o nb o l t s , 4 3 51204 5 1 A
T h e s ea r e t h e s t o c k b o l t s w i t h
rubber bonded to them which
dampensout vibrationsat certain
f requenciesand prolongs bolt
life.
gears,
4. Stationary
front:435210500
rear:435210550
Comparedto the stock gears,
t h e s e h a v e t h e f o l l o w i n gd i f f e r ences:
( 1 ) F o rs t r e n g t ht,h e m a t e r i aal n d
heattreatmentis different.
(2) A machinedgroovearoundthe
bearing;this featureenhances
b e a r i n gl i f e .
The intakeand exhaustt i m i n g i s
as follows:
IntakeOpens86' BTDU
C l o s e7
s5'ABDC
2 . S i d eh o u s i n g s ,
front:435210200
intermediate:
435210400
r e a r : 4 8 0110 3 0 0
StationaryGear
ENGINE
O i lp a n , 4 3 5 2 1700 0
This is an increasedcaPacitYPan
t o m a i n t a i np r e s s u r ue n d e r a c i n g
c o n d i t i o n sp,a r t i c u l a r lwy h i l ec o r nering.
Baffleplate,435210709
T h i sb a f f l ep l a t ew i l l m a i n t a i na n
oil supPlYaroundthe oil
adequate
p u m p p i c k u pw h i l e c o r n e r i n go r
braking.
a
O
0
BotatlnggrouP.
1 . B a l a n c ear s s e m b l Y , 4 3 5 201110
Thesepiecesdifferf rom stockbY
b e i n gb a l a n c e dt o a c l o s e rt o l e r ance.
2 . R o t o r , 4 3 5 2 1 10 0
Thecompetitionrotorhasthe fol'
lowingfeatures:
( 1 ) T h e c o m b u s i o nc h a m b e r i s
the Medium DeeP Recess
(MDR)tyPe.
(2) lt has a snapringto retainthe
i n t e r n agl e a ri n P l a c e .
(3) Theapexsealgrooveis chrome
platedto reducewear.
R o t o rb e a r i n g ,
s t a n d a r d1:0 1 11 ' l1 1 1
o v e r s i z e1:0 5 87 8 1 3 5
The oversizebearingis available
t o p r o v i d et h e c o r r e c to i l c l e a r '
a n c e ,a n d i s l a r g e ri n d i a m e t ebr Y
30p
2 13 0 1
A p e xs e a l , 4 3 5 1
The apexseal is madeof carbon
a n di s 3 . 0m m t h i c k .
A p e xs e a ls p r i n g , 4 3 51213 0 4
T h i s s p r i n gi s d e s i g n e ds P e c i f i '
c a l l yf o r t h e 3 . 0m m c a r b o na P e x
S i d es e a l 4, 8 0 11 13 1 1
t o t h e s t o c ks e a l ,t h i s
Compared
treated
s i d es e a li s m o l y b d e n u m
wearresistance.
for increased
1 81 4 6
7. C o r n esr e a l ,1 B B 7
The corner seal has a sPraYed
c o a t i n gf o r s e l f l u b molybdenum
r i c a t i o np r o p e r t i e s .
O u t e ro i l s e a ls P r i n g ,
f r o n t : 4 3 51213 5 3
rear:435211 363
T h e i n c r e a s e dp r e s s u r eo f t h i s
s p r i n g , d i ffe r e n t f r o m o r i g i n a l ,
to B kg/cm'
13kg/cm' ascompared
f o r t h e s l a n d a r do i l s e a l s p r i n g ,
prohibitscombusiongas blowbY.
F o r t h e i n n e ro i l s e a l ,t h e s t o c k
s p rn
i gissatisfactory.
2 14 0 0
E c c e n t r isch a f t , 4 3 5 1
T h em a t e r i aal n d c o n fi g u r a t i o no f
t h i s s h a f t a r e i d e n t i c a tl o s t o c k ,
b u t t o r e d u c et h e l i k e l i h o o do f
bearingseizure,the rear half of
t h e r e a rm a i nj o u r n a il s m a c h i n e d
as shown
in diameter,
20p.smaller
i n t h ei l l u s t r a t i o(na. D = A - B )
ENGINE
1 0 . D r i v ep u l l e y4, 3 5 21 16 0 1
T h i s p u l l e yh a s t h e f o l l o w i n gd i f ferencesf romthe stockversion:
(1)Thematerialis aluminumalloy
to reduceweightand rotating
inertia.
(2) The oil seal lip's contactarea
has beentreatedfor wear resistance.
( 3 ) T h ed i a m e t eirs 9 0m m .
435211 755
11. Flywheel,
This flywheelis fabricatedfrom
s t e e l b u t i s s i g n i f i c a n t l yl i g h t e r
t h a n s t o c kt o r e d u c er o t a t i n gi n ertia.
12. Needlebearing,082278184
T h e n e e d l eb e a r i n gh a s a h i g h e r
loadcapacityto withstandsevere
c l u t c he n g a g e m e n t s .
C. Intakeand exhaustgroup.
1 . I n t a k em a n i f o l d4, 3 5 21 31 0 0
T h i s m a n i f o l dh a s t h e f o l l o w i n g
features:
( 1 ) l t i s c a s tf r o ma l u m i n u ma l l o y .
(2) lt has beendesignedto accept
a n dw o r kw i t h t h e D D W4 8 l D A
carburetor.and to match an
e n g i n e i n s t a l l a t i o na n g l e o f
4"40' .
( 3 ) T h e l e n g t ho f t h e i n t a k ep a s sageshas been determined
f o r o p t i m u mt u n i n g a n d e f f i c i e n c ya t t h e d e s i g n e de n g i n e
speeds.
2. Gaskets,
r o t o rh o u s i n gt o i n t a k em a n i f o l d :
086278205
i n t a k em a n i f o l dt o c a r b u r e t o r :
086278206
.
78240
3. Carburetor
support,0862
T h i ss u p p o r rt e d u c e st h e t r a n s f e r
o f e n g i n ev i b r a t i o ntso t h e c a r b u r etor and thereby preventsfuel
s u r g i n ga n db u b b l i n g .
4 . E x h a u sht e a d ear n dp i p e ,
header:435278250
pipe:4352
78260
S o m eo f t h e m a i nf e a t u r e so f
exhaustsystemare:
( 1 ) B o t ht h e h e a d e ra n d p i p ea r e
fabricatedfrom stainlesssteel.
(2) Theheaderis a tubulardesign,
a n d t h e p i p e t e r m i n a t e si n a
megaphone.
(3) The headerand pipe are jointo
e d b y a s l i d i n gc o n n e c t i o n
a l l o wf o r e n g i n ev i b r a t i o na n d
movement.
5. Exhaustsystemsupportbrackets
Seepage10for details.
D. Lubricationgroup.
1 . O i l p u m p ,1 0 5 87 82 2 0 A
The shaft and rotorsin the comp e t i t i o no i l p u m pa r e m o r er e s i s t a n tt o w e a ra n ds e i z i n g .
2. O i l p r e s s u r er e g u l a t o ar s s e m b l y ,
435214 250
T h i s r e g u l a t o rw i l l m a i n t a i no i l
pressureat 6.5 -r 0.5kg/cm' .
3. E n g i n eo i l c o o l e r1
, 0 5 87 8 1 8 0
T h i s l a r g e r - t h a n - s t occoko l e rw i l l
i n c r e a s ec o o l i n gc a p a c i t yb y 5 0
percentoverstock.
E. Coolinggroup.
1 . W a t e rp u m p , 4 8 01150 1 0
T h e c o m p e t i t i o nw a t e r p u m p i s
aluminum
alloy.
2. W a t e rp u m pp u l l e y , 4 8 0115 1 5 1
T o r e d u c ew e i g h t t h i s p u l l e yi s
m a d e f r o m a l u m i n u ma l l o y ,a n d
its larger-than-stock
130mm diam e t e rw i l l e n h a n c eV - b e l lt i f e a n d
reduce the speed of the water
pump.
3. Radiator,
105878 190
T h e a l u m i n u ma l l o y c o m p e t i t i o n
radiator's
largercorewill increase
enginecoolingcapacityby 60 percentoverstock.
V-belt,105878 154
T h i sn o t c h e dV - b e l its m o r er e s i s tantto heat.stretchandvibration.
F. Electricalsystem.
1 . l g n i t i o nc o i l , 4 8 0 11 B1 0 0
This higheroutput coil is exclus i v e l y d e s i g n e df o r u s e w i t h t h e
Mazdacompetitioncapacitivedisc h a r g ei g n i t i o n( C D l ) .
2 . H i g h t e n s i o nw i r e s ,
c o i l - t o - d i s t r i b u t o4r 3: 5 21 B1 1 0
d i s t r i b u t o r - t o - s p apr kl u g s :
4 8 0 11 B1 5 0
These high tensionwires have a
m e t a l w i r e c o r e t o r e d u c ev o l t a g e
drop.
3 . D i s t r i b u t o r , 4 B 01l B2 0 0
These are the main featuresof the
distributor:
( 1 ) l t i s b r e a k e r l e s s ,h a v i n g a
m a g n e t i ct r i g g e r .
(2) There is no advance mechanism.
ENGINE
4. l g n i t o a
r n dl e a dw i r i n g ,
ll.
i g n i t o r : 4 8 01188 0 0
l e a dw i r i n g : 4 8 01188 7 0
T h i s f u l l y t r a n s i s t o r i z eidg n i t i o n
will providea stable secondary
v o l t a g ea t h i g h e n g i n es p e e d s .
T h e l e a dw i r i n gh a r n e s si s s P e c i '
f o rt h i s i g n i t i o n .
f i c a l l yi n t e n d e d
andalternatorstraP,
5 . Alternator
a l t e r n a t o r : 3 9 9 731080
s t r a p : 4 8 01183 6 1
A l t e r n a t opr u l l e yp a r tn u m b e r :
53A
0833-78-1
T h ea l t e r n a t ooru t p u ti s 3 5 a m P s ,
a n di t s p u l l e yd i a m e t eirs 7 5m m .
6 . Starterstay,43521B401
'1281
17383
spacer,
Thestarterstayreducesvibration
and preventspossiblebreakage
case.
of the transmission
the staY,the
installing
Note:When
spacermust be insertedbetween
the stayandthe startermotor.
Additional Required Parts.
These Parts must be acquired
f r o mo u t s i d es o u r c e s .
1. Carburetor.
T h i s e n g i n eu s e s ' aW e b e r4 8 l D A
o f t h ef o l l o w i n gs P e c i f i c a t i o n s :
48x43
Eorex Venturi(mm)
F-8
E m u l s i o nt u b e
M a i ni e t
fi230
Mainair corrector.iet
l d l ej e t
#130
#80
l d l e a i r c o r r e c t o ri e l
#120
Acceferatornozzle
#50
#300
mm
21-23 fromthe
uppersurfaceof the
floatchamber.
N e e d l e& s e a t
Float level
2. Tachometer.
We recommendusing a mechanicaltachometer.
gauges.
3 . Temperature
M i n i m u mr e q u i r e m e n tisn c l u d e
gauges.
waterandoil temPerature
ea u g e .
4. O i l p r e s s u r g
We recommenda mechanical
gaugeof the BeldentubetYPe.
lll. Machining and FabricationOperations and Pr ocedur es
7. Sparkplug,435218600
Theheatrangeof this Plugis 11.5,
w h i c hi s c o l d e rt h a ns t o c k .
8 . Fuelpump,43521B250
T h i s f u e l p u m Ph a s a n o u t P u to f
Two of them are
100 liters/hour.
n e e d e dt o s a t i s f Yt h e r a c i n ge n '
g i n e ' sm i n i m u mf u e lf l o w r e q u i r e mentof 180liters/hour.
A. Fabrication of oil separator tank.
1 . U s e t h e s t o c k o i l f i l l e rP i P e .
2 . T h e o r i g i n a lf i l l e r p i p e i s t o o l o n g
and must have a 40 mm section
removed from the middle. Cut it,
r e w e l da n d d r i l l h o l e sa s s h o w n i n
the illustration.
3 . F a b r i c a t et h e t a n k a s s h o w n ,a n d
w e l d i t t o t h e f i l l e rP i P e .
4. Afterwelding,checkfor anYPos'
s i b l eo i l l e a k s .
ii
,,i
(F"y'
i''-.1
-_*,,
n,
f(
Y,'t
))t
ENGINE
B. EGRport block-offplate.
1 . l f y o u r i n t e r m e d i a theo u s i n gh a s
a n E G Rp o r t ,i t m u s t b e b l o c k e d
off with a plate.We recommend
l y. 0 m m
a l u m i n u ma p p r o x i m a t e 3
thick.
2 . W h e n i n s t a l l i n gt h e b l o c k - o f f
p l a t e ,u s e a g a s k e to r s o m es i l i '
conesealant.
Meteringpumpholecover.
1 . l f t h e m e t e r i n gP u m Ps h a f ti s n o t
u s e da s a m e c h a n i c a l t a c h o m e t e r
drive,the hole must be covered
w i t h a p l a t e .M a k e t h e P l a t eo f
l Y. 0 m m
a l u m i n u ma p p r o x i m a t e 3
thick.
2 . A g a s k e tm u s t b e u s e d w i t h t h e
holecoverplate.
D. Weber carburetorfloat bowl extension.
Forcourseswith verytightor long
c o r n e r st,h i s f l o a tb o w le x t e n s i o n
w i l l h e l pp r e v e nftu e ls t a r v a t i o n .
The float bowl extensionfabricais as follows:
tion procedure
( 1 ) C u ta n a p p r o p r i a theo l eo n t h e
s i d eo f t h ef l o a tc h a m b e r .
(2) Fabricatethe bowl extension
fromsheetaluminumas shown
i n t h ei l l u s t r a t i o n .
(3) W e l d t h e b o w l e x t e n s i o nt o
the floatchamberat fourpoints
o n l y ;i f y o uw e l da l l a r o u n dt h e
maydistort.
carburetor
(4) A f t e r w e l d i n g ,s e a l t h e b o w l
extensionto the float chamber with ThreeLoy.The Three
Loy may be held in placewith
s i m i l a ru n t i l
c l a yo r s o m e t h i n g
it hardens.
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F. Cold air induction box.
This is one of the best waYs we have
found to utilize the high Pressure
area at the front of the car for intake
a i r , b u t i t s s i z e , l o c a t i o na n d d e s i g n
a r e i m p o r t a n tt o m a x i m u m P e r f o r m '
a n c e .T h e i m p o r t a n tp o i n t s o f i t s d e s i g n a r e o u t l i n e db e l o w .
1 . T h e a i r i n t a k es e c t i o ns h o u l db e
l o c a t e di n t h e r i g h t h a n ds l d e o f
t h e r a d i a t oor P e n i n g .
the air
fabricating
2. We recommend
i n t a k ea n dc a r b u r e t ocro l da i r b o x
f r o mf i b e r g l a s s .
T
3. h ed e s i g no f t h e c a r b u r e t ocro l d
a i rb o xi s s h o w nb e l o w :
5 . F a b r i c a t et h e i n t a k e s e c t i o nt o
t h e d i m e n s i o n ss h o w n , a n d a t '
t a c ht o r i g h ts i d ep a n e la s s h o w n
6 . A n a i r f i l t e r e l e m e n ti s a b s o l u t e l y
n e c e s s a r yl.f d i r t g e t s i n t o t h e e n g i n e t h r o u g hl h e i n t a k e ,c o m p r e s s i o n i s l o s t f r o m w e a ro n t h e i n t e r '
n a l g a s s e a l s .F o r a f i l t e r e l e m e n t
m a t e r i a l ,F i l t r o n h a s w o r k e d v e r Y
well. Locate the element at the
e n t r a n c e t o t h e c a r b u r e t o rc o l d
a i r b o x .T h e i n t a k es y s t e m s h o u l d
b e s e a l e dv e r Yt i g h t t o c o m P l e t e l Y
p r o h i b i ta n y d i r t o r d u s t f r o m e n t e r i n gt h e e n g i n e ,s o c h e c k f o r a i r
l e a k s ,h o l e so r o t h e ro P e n i n g s .
4 . T h e c o n n e c t i n gd u c t c a n b e a n Y
t y p e o f f l e x i b l eh o s e w i t h a m i n i '
0 m.
r f 1 1 0 - 1 2m
m u m d i a m e t eo
o
N
I
o
11
ENGINE
2. Installthe sidepanelsin the same
l o c a t i o na n d m a n n e a
r s thestock
versions.
G. Competition radiator installation.
1 . F a b r i c a t et h e l e f t a n d r i g h t s i d e
panelsas shown in the illustrat i o n s b e l o w . A l l d i m e n s i o n sa r e
g i v e n i n m i l l i m e t e r sT. h e h o l e i n
the right side panel is for the intake system.
S i d ep a n e l( R i g h t )
H.
Competitionoil coolerinstallation.
Thereare two possiblelocationsfor
t h e o i l c o o l e ra s s h o w ni n t h e i l l u s t r a t i o n sb e l o w . l n b o t h c a s e s ,t h e
competitioo
n i l c o o l e rh o s e sc a n b e
u s e d , i n e i t h e rl h e v e r t i c a l { y p eo r
h o r i z o n t a l - t ym
p eo u n t i n g .
V e r t i c a lt y p e
H o r i z o n t atl y p e
il
ENGINE
1 . Thefirst locationis referredto as
t h ev e r t i c a l - t y pwei,t ht h eo i l c o o l e r m o u n t e di n f r o n to f t h e r a d i a t o r
a n d a t t a c h e dt o t h e r a d i a t o sr u p port bracketswith rubbermounts.
2. Thesecondlocationis referredto
ae
nd is suas the horizontal-typ
perior to the vertical-type,
as it
lowersthe oil temperaeffectively
t u r eb y a p p r o x i m a t e 1
l y8 ' F ( 1 0 '
c).
( 1 ) T h ei n s t a l l a t i oonf t h eo i l c o o l er in the horizontallocation
r e q u i r e fsa b r i c a t i oonf m o u n t i n g b r a c k e t sa s s h o w ni n t h e
illustration.
( 2 ) l n s t a l lt h e b r a c k e t sb y u t i l i z i n g t h e b u m p e rb r a c k e b
t olts,
a s s h o w ni n t h e i l l u s t r a t i o n .
d e p o s i t sa r er e s i s t a ntto c l e a n i n g
w i t h e i t h e ro f t h e s es o l v e n t su, s e
sandpaperwettedwith
#400-#600
oil.
3. Measurements.
(1) Surfaceflatness(sidehousing
distortion).
a) To check surfaceflatness
u s e a n a c c u r a t es t r a i g h t
edge and a set of feeler
gauges.
b ) C h e c k t h e s u r f a c ei n t h e
f o u r l o c a t i o n ss h o w n i n
F i g u r e1 . T h e l i m i t f o r d i s t o r t i o ni s 0 . 0 4m m , a n d i f
t h i s l i m i t i s e x c e e d e da t
a n yp o i n t ,t h e s i d eh o u s i n g
m u s tb e r e p l a c e d .
o
1
Bumpermountingbracketholes
6
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Oilcooler
o
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o
& #
o
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Figure 1
(2) Steppedwear from side seal.
a) To check the side seal wear,
u s e a d i a l i n d i c a t o rw i t h a
sharptip and a suitabledial
indicator stand, and ch'eck
a s s h o w n i n F i g u r e2 .
Oilcooler
N o t e :A l l d i m e n s l o n sa r e i n m m .
C h e c ks a n d Me a su re me n ts.
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A. Sidehousing.
1 . C h e c k s( t o b e d o n eb e f o r ec l e a n ing)'
(1)In the area wherethe side
h o u s i n gc o n t a c t sa n d m a t e s
w i t h l h e r o t o rh o u s i n gc, h e c k
a l l a r o u n dt h e c o o l a n t P a s s a g e sf o r s i g n so f c o o l a n to r
gas leakageor surfaceabrasion.
( 2 ) O n t h e r u b b i n gs u r f a c ec, h e c k
f o r e x c e s s i vw
e e a ro r s c u f if n g
on or in the paths traced bY
the rotorseals.
2. Cleaning.
Clean off any surface dePosits
w i t h M E Ko r p a i n tt h i n n e r l. f t h e
\*r-.X"#
Figure2
b) The allowablelimit for wear
i s 0 . 1m m , a n d i f t h i s l i m i t
i s e x c e e d e d t, h e s i d e h o u s ing mustbe replaced.
13
ENGINE
Note:
a ) P a y p a r t i c u l aar t t e n t i o nt o
t h e s p a r kp l u g s i d e o f t h e
s i d e h o u s i n g t; h i s i s t h e
c o m b u s t i o na r e a a n d i s
u s u a l l yt h e l o c a t i o no f t h e
greatestwear.
b) lf excessivewear ratesare
m e a s u r e do v e ra r e l a t i v e l y
s h o r tp e r i o do f t i m e ,f o r i n stance 0.1 mm after 2000
m i l e so r l e s s ,i t m a y b e a n
i n d i c a t i o no f d i r t o r o t h e r
c o n t a m i n a nitnst h ee n g i n e
a n d t h e i n t a k ea i r f i l t e r i n g
s y s t e ms h o u l db e c h e c k e d .
A - ( M i n i. n s i d ed i a . )- ( M a x .
d i a .o f j o u r n a l )
B = ( M a x .i n s i d ed i a . )- ( M i n .
d i a .o f j o u r n a l )
B o t ht h e A a n d B d i m e n s i o n s
must be in the rangeof 0.050 . 0 8m m .
3 . B e a r i n gr e p l a c e m e n t .
( 1 ) B e a r i n gr e m o v a l .
T o r e m o v et h e b e a r i n gu, s e a
p r e s sa n d t h e b e a r i n gp u l l e r ,
part number49 0813235.Removethe adaptorringfromthe
puller,and pressfromthe gear
s i d ea s s h o w ni n F i g u r e5 .
B. Stationarygears(frontand rear).
1. Checks.
Visually,
checkfor any indications
o f d a m a g eo r c r a c k i n go n t h e
teeth.
2. Measurements.
( 1 ) I n s i d ed i a m e t eor f b e a r i n g .
a ) W i t ha n i n s i d em i c r o m e t e r ,
m e a s u r et h e f o u rp o i n t sa s
s h o w ni n F i g u r e s3 a n d4 .
Figure5
( 2 ) B e a r i n gi n s t a l l a t i o n .
P a y p a r t i c u l a r l yc l o s e a t t e n t i o n t o t h e p o s i t i o n i n go f t h e
clinchlocksectionof the bearI n s t a l lt h e b e a r i n gw i t h t h i s
procedure.
a ) A t t a c ht h e a d a p t o rr i n g t o
t h ep r e s st o o l .
b) Makecertainthe clinchlock
r osition.
i s i n t h ep r o p e p
c ) P r e s st h e b e a r i n ga l l t h e
w a yd o w nu n t i lt h e a d a p t o r
ring contacts the gear
f l a n g ea
, s s h o w ni n F i g u r e
6.
Figure 3
a.tnJl::l.j'i::
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ir.r,.',ji
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Figure4
l f t h e o i l c l e a r a n c ies i n c o r r e cot r
t h e s u r f a c ei s f l a k i n gt,h e b e a r i n g
m u s tb e r e p l a c e d .
( 2 ) O i lc l e a r a n ccea l c u l a t i o n .
Determine
the oil clearance
by
t h ef o l l o w i n gf o r m u l a :
Figure 6
ENGINE
C . M e a s u r e m e not f A F ( a F i s t h e
smallest clearancebetween the
rotorandthe rotorhousingsurface).
(1)Install outer oil seals and
s p r i n g si n o n e s i d e o f t h e
r o t o r . T h i s w i l l p r e v e n tt h e
rotor contacting and thus
s c u f f i n gt h e s i d e h o u s i n ga s
you rotateit for measurement.
(2) Invertthe rotorand insertit in
t h e r o t o rh o u s i n gT. h es p r i n g s
w i l l h o l dt h eo i l s e a l si n p l a c e .
(3) Measure a F with a feeter
g a u g e ,a s s h o w ni n F i g u r e7 .
There are four measuring
p o i n t s ,t w o o n e a c h s i d e , a t
25 mm aboveand below the
horizontal
centerline.
as shown
i n F i g u r e8 .
S"o^
Figure 7
D. Rotorhouslng(frontand rear).
1. Checks(to be done beforecleaning).
(1) Trochoidsurface.
a ) C h e c kt h e s u r f a c ef o r f l a k i n g o f t h e c h r o m ep l a t eo r
d e n t s ,s c r a t c h e so r o t h e r
imperfections.
b ) C h e c kf o r g a s l e a k a g eo r
deposits:
c) Check the traitingspark
p l u g h o l e f o r c r a c k s ,a s
s h o w ni n F i g u r e9 .
T r a i l i n gp l u g h o l e .
Figure9
T h e m a x i m u ma l l o w a n c ef o r
c r a c k si s 8 m m ; i f l o n g e rt h a n
t h a t ,r e p l a c et h e h o u s i n g .
(2) Rotorhousingsides,frontand
rear.
C h e c kf o r a n y i n d i c a t i o n so f
gas or coolantleakage,or for
a n y a b n o r m a la b r a s i o n s .l f
a n yo f t h e s ec o n d i t i o n se x i s t ,
d e t e r m i n et h e c a u s e b e f o r e
proceeding.
2. Cleaning.
( 1 ) C l e a nc a r b o no r a n y o t h e rd e p o s i t sw i t h M E Ko r p a i n tt h i n ner.
(2) Removeall scaleand rust trom
the coolantpassagesand waterjackets.
3 . M e a s u r e m eo
n ft w i d t h .
lr
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ir
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lt
li
i,
Figure I
Theallowableclearancerangefor
A F is 0.40-0.70
mm.
Notes:
a ) l f a F i s l e s st h a n0 . 4 0m m ,
the rotor may contact the
h o u s i n ga t h i g hs p e e d .
b) Mark F or R, for front or
reat, on the rotors after
m e a s u r i nfgo r a F .
c) Usecarenot to damagethe
interiorsurfaceof the rotor
housing with the feeler
gauge.
a) This measurementrequires
a 50-75mm micrometer.
b) Measurethe width,or thickness, of the housingat
p o i n t sA , B , C a n d D a s
s h o w ni n F i g u r e1 0 .P o i n t s
C and D are each 20 mm
s t e p s , i n d i v i d u a l l yb e g i n ning at point B. Compare
t h e d i m e n s i o na t p o i n t A
w i t h t h e s m a l l e s to f t h e
o t h e rt h r e e w
, h i c h e v ei rt i s .
l f t h e d i f f e r e n c ei s m o r e
t h a n0 . 0 6m m , t h e h o u s i n g
m u s tb e r e o l a c e d .
15
ENGINE
-+I
Figure 10
N o t e :T h e m e a s u r i n gP o i n tf o r
t h e m i c r o m e t e ri s o n t h e i n n e r
side of the rubberseal groove.
After measuring, mark the
housingF or R to denotethe
front and rear sides.
E. Rotor.
1. Checks (to be done before clean'
ing).
( 1 ) R o t o rc o n d i t i o n .
C h e c k f o r g a s l e a k a g e ,a n Y
damage to the rotor, and the
s t a t e o f c o m b u s t i o n .F i n a l l Y ,
checkfor any marksthat would
indicate the rotor had been
contacting the side of the
h o u s i n g ;t h e s e m a r k s m a Y b e
found,in particular,in the area
of thetip of the rotor.
(2) Internalgear.
C h e c kc a r e fu l l y f o r c r a c k s ,e x , e n t s ,n i c k s
tremeabrasionsd
and scratches and other dam'
age to the gear and teeth.
(Cracks will sometimes aPpear around the sPring Pin
hole and in the sPringPin it'
s e l f. )
2. Cleaning.
W h e n c l e a n i n gt h e r o t o r , d o n o t
u s e a s t o n e , s a n d P a P e ra, n Y t o o l
or abrasives to remove carbon
from the apex seal groove. This
Figure 11
16
g r o o v es h o u l d b e c l e a n e do n l Y
or MEK.
witha brushandkerosene
3. Measurements.
( 1 ) U s i n ga 5 0 - 7 5m m m i c r o m e t e r ,
measurethe rotorat the three
p o i n t ss h o w ni n F i g u r e1 1 .
( 2 ) C a l c u l a t ea R b y t h e f o l l o w '
i n gf o r m u l a :
A R = ( R o t o rh o u s i n gw i d t h
at pointA) - (Max.rotorwidth
a t a n y p o i n tm e a s u r e di n t h i s
step)
T h ea l l o w a b l er a n g eo f a R i s
0 . 1 3 - 0 . 1m7m .
( 3 ) M e a s u r e m eo
n ft a H .
T h i s m e a s u r e m e nr e
t q u i r e sa
and a set of feel'
straightedge
er gauges.Checkit as shown
in Figure12. The allowable
r a n g eo f a H i s 0 . 1 5 - 0 . 2m0m .
Figure 12
F. Rotor bearing.
1. Checks.
Look for abnormal abrasions or
a n y s i g n so f f l a k i n go r s e i z i n g .
2. Measurements.
( ' l ) M e a s u r et h e b e a r i n gw i t h t h e
f o l l o w i n gP r o c e d u r e :
a) Use an inside micrometer
and measurethe bearingat
t h e s i x ( 6 )p o s i t i o n ss h o w n
i n F i g u r e s1 3a n d 1 4 .
Figure 13
ENGINE
Figure l4
c) After removing the beari n g ,c l e a nt h e m a t i n gs u r faceof the rotor.
( 2 ) B e a r i n gi n s t a l l a t i o n .
a) First, install the adaptor
r i n go n t h ep r e s st o o l .
b) Pressfromthe internal'gear
side.
c) Make certain the clinch
l o c ki s p r o p e r l py o s i t i o n e d .
d ) P r e s sa l l t h e w a y d o w n u n til the adaptorringcontacts
t h e b e a r i n gb o s s ,a s s h o w n
i n F i g u r e1 6 .
b) The bearingmust be replace d i f f l a k i n g i s e v i d e n to v e r
o n e - h a l fo f i t s t o t a l a r e a o r
i f t h e o i l c l e a r a n c e sa r e i n correct.
( 2 ) C a l c u l a t et h e o i l c l e a r a n c eb y
t h e f o l l o w i n gf o r m u l a :
O i l c l e a r a n c eA = ( M i n .i n s i d e
d i a . ) - ( M a x .j o u r n a ld i a . )
Oil clearanceB = (Max.inside
d i a . - ( M i n .j o u r n a ld i a . )
T h e a l l o w a b l er a n g e o f
a n c e si s 0 . 0 7 - 0 . 1m
0 m.
Note: There is an oversize
b e a r i n ga v a i l a b l ep, a r l n u m b e r 1 0 5 87 8 1 3 5 ,i f t h e s t a n d a r ds i z ew i l l n o t g i v et h e p r o p e rc l e a r a n c e s .
replacement.
3. Bearing
(1)Bearing
removal.
a ) D r i l lo u t t h e l o c k i n gs c r e w
withaTmmdrill.
b) Use the special tool, 49
0813240,to pressout the
bearing.
Figure 16
( 3 ) L o c k i n gs c r e wi n s t a l l a t i o n .
a) The bearingshould be locked firmly in place by one
l o c k i n gs c r e w o p p o s i t et h e
clinch,as shown in Figure
1 7 . T h i s r e q u i r e sd r i l l i n g
andtapping.
i
J
l;
il
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d
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ti
iii
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Notes:
a) Before pressing out the
bearing,removethe adapt o rr i n g .
b) Pressfrom the side oppos i t e t h e g e a r ,a s s h o w ni n
F i g u r e1 5 .
Figure 15
Figure 17
b ) B e f o r ed r i l l i n g ,u s e t h e s p e c i a l e x p a n d e rt o o l t o p r e vent the bearing from deforming.
c) Drill a 3.5 mm hole to a
d e p t ho f 8 m m .
d ) C u t t h e t h r e a dw i t h a n M 4 0.7 tap and blow the hole
c l e a nw i t h c o m p r e s s e da i r .
e) Insertand tighten the screw
a n dc l i n c h .
17
ENGINE
f ) S l i g h t l ys c r a p ea n ds m o o t h
the surfaceoverthe screw.
g ) C l e a nt h e r o t o rt h o r o u g h l y
w i t h k e r o s e n ea n d b l o w
c l e a na n dd r yw i t ha i r .
G . Apexseal.
1. Checks.
B a s i c a l l yt h, es e a ls h o u l db ev i s u a l l yc h e c k e df o r w e a r ,c h i p p i n gi n
the groove,cracks,and any other
irregularities.
2. Cleaning.
R e m o v et h e c a r b o nw i t h M E K o r
painthinner.
3. Measurements.
( 1 ) M e a s u r eh e i g h t , l e n g t h a n d
w i d t h a s s h o w ni n F i g u r e1 8 .
T h i sw i l l r e q u i r et w o m i c r o m e ters, a 0-25mm and a 50-75
m m . M a r ke a c h a p e x s e a l t o
d e n o t ei t s p o s i t i o na n d l o c a tion on the rotor.Measureas
follows:
a ) H e i g hA
t a t b o t he n d s .
b ) L e n g t hB a t o n ep o i n t .
c) WidthC at bothends.
( 3 ) A d j u s t i n ga S .
l f a S i s l e s st h a n t h e l o w e r
l i m i t o f t h e a l l o w a n c ei,t c a n
b e a d j u s t e db y s a n d i n gt h e
end of the apex seal with
sandpaper,
#400-#600
as shown
i n F i g u r e1 9 .
Note:Be carefulnot to remove
t o o m u c h m a t e r i a lf r o m t h e
a p e xs e a l ,t h e r e b yi n c r e a s i n g
theclearance
overlimitswhich
w o u l d n e c e s s i t a t er e p l a c i n g
t h es e a l .
Figure 19
Figure 18
a S, the
(2) Measurementof
c l e a r a n c eb e t w e e n t h e a P e x
s e a la n d t h e s i d e h o u s i n g .
a) This measurementrequires
a 5 0 - 7 5m m m i c r o m e t e r .
b) Calculate a S by the foll o w i n gf o r m u l a :
A S = (Rotorhousingwidth
(Apex seal
at point A)
length)
T h e a l l o w a b l er a n g eo f a S i s
0 . 1 0 - r 0 . 0 1m m .
N o t e : T h e r e b u i l d a b l el i m i t o f
A S i s 0 . 1 5m m .
18
(4) M e a s u r e m e not f a G , t h e g a p
betweenthe apex seal and the
apex seal groove.
T h i s m e a s u r e m e n tr e q u i r e sa
f e e l e rg a u g e ,a n d i s d o n e a s
s h o w n i n F i g u r e2 0 .
T h e a l l o w a b l el i m i t o f A G i s
0.065 -r 0.005mm.
N o t e : l f A G i s i n t h e r a n g eo f
0.06-0.07mm, the 0.06 gauge
will easilyfit into the groove;
the 0.07 gauge will be very
tight.
ENGINE
(2\ U s i n g a n i n s i d e m i c r o m e t e r ,
t h e i n s i d eo f t h e c o r measure
n e r s e a l g r o o v ea s s h o w n i n
F i g u r e2 3 .
(3) C a l c u l a t i oonf A C ( t h ec l e a r a n c eb e t w e e nt h e c o r n e rs e a l
a n dt h eg r o o v e ) .
A C = ( l n s i d ed i a .o f g r o o v e )
- ( C o r n esre a ld i a . )
T h e a l l o w a b l er a n g eo f a C i s
mm.
0.02-0.048
( 5 ) A d j u s t i n ga G .
l f t h e c l e a r a n c ei s l e s s t h a n
t h e a l l o w a b l er a n g e ,s a n do f f
the apexseal using#400-#600
s a n d p a p e or n a k n o w n f l a t ,
s m o o t hs u r f a c ea s s h o w n i n
F i g u r e2 1 . W h i l e d o i n g t h i s ,
t h e s e a l s h o u l db e m e a s u r e d
often to preventremovingtoo
m u c hm a t e r i a l .
D i a lb o r eg a u g e
L o c a t i o no f n e e d l e s .
Figure23
l.
i
.l
t
rll
,:,1
tl
H. Cornerseal.
1. Inspection.
Thecornersealshouldbe inspecte d f o r c r a c k so r a n y s i g n so f e x cessivewear.
2. Cleaning.
U s e M E K o r p a i n tt h i n n e rt o r e m o v e a l l c a r b o nd e p o s i t s ,t h e n
w i p ec l e a nw i t h a c l o t hd i p p e di n
t h es a m es o l u t i o n .
Note:Do not usesandpaper.
3. Measurement.
( 1 ) M e a s u r et h e h e i g h ta n d d i a ' meter of the corner seal as
s h o w ni n F i g u r e2 2 .
.'rii
'. l
.rl
".i:
r;
1;l
' t
-:i
, ,;
,i
t.;i
';;
'l
P
\-€I
ill_]
Figure22
Side Seal.
1. Inspection.
C h e c kt h e s i d es e a lf o r w e a ra n d
damage.
2. Cleaning.
Removeall carbondepositsusing
M E Ko r p a i n tt h i n n e rt,h e n w i P e
c l e a nw i t h a c l o t h s o a k e di n t h e
s a m es o l u t i o n .
3. Measurement.
( 1 ) M e a s u r e m e notf a E ( c l e a r ance betweena corner seal
a n da s i d es e a l ) .
M e a s u r ae E w i t h a f e e l e r
g a u g ea s s h o w ni n F i g u r e2 4 T h ea l l o w a b l er a n g eo f a E i s
0 . 0 5 - 0 . 1m
5 m, but thereis a
m a x i m u mu p p e r l i m i t f o r r e b u i l d so f 0 . 2 0m m .
ENGINE
( 2 ) A d j u s t i n ga E .
a E i s a d i u s t e db y r e m o v i n g
metal from the ends of the
s i d e s e a l .T h e i d e a l m e t h o d i s
t o u s e a r o t a r y g r i n d e r ,w i t h
the stone the same diameter
as the corner seal. However,
a n a c c e p t a b l ea n d m o r e c o m mon method is as described
b e l o wa n d s h o w n i n F i g u r e2 5 .
a) Useaflatfile.
b ) F i l et h e e n d o f t h e s i d e s e a l
so its endwill fit the corner
seal; this angle should be
i d e n t i c a lt o t h e o r i g i n a la n g l e o n t h e s i d es e a l .
Figure 26
h e i g h to f t h e s p r i n g .
2. fo check the seal stroke of the
side, cornerand oil seals,use a
v e r n i e rc a l i p e r .E a c h s e a l s h o u l d
have a minimum seal stroke of
0 . 5m m .
Note: Check each seal to confirm
that it will move up and down
s m o o t h l yi n i t s g r o o v ew i t h f i n g e r
pr essur e.
K. Eccentric shaft.
1 . Inspection.
Figure25
( 3 ) P o i n t st o r e m e m b e r :
a) Use care not to bend or
otherwisa
e l t e rt h e c u r v ei n
the side seal: the curve
s h o u l dm a t c h t h a t o f t h e
groove.
b) l f q u i t e a b i t o f m a t e r i a l
needs to be removed, you
should first cut the seal.
then file to its final shape,
t o a v o i d b e n d i n go r o t h e r w i s e d a m a g i n gt h e s e a l .
c) A f t e r f i n i s h i n gf i t t i n g e a c h
s i d e s e a l ,m a r k i t l o c o r r e s pond to its particulargroove
on the rotor for later assemblv.
J. Checking the seal stroke.
T h e s e a l s t r o k e i s d e f i n e da s t h e
a v a i l a b l et r a v e lo f a s e a l s p r i n g i n
, n d i s a f u n c t i o no f t h e
its groovea
sealspring.
1 . T o m e a s u r et h e f r e e h e i g h to f t h e
a p e x s e a l s p r i n g ,p l a c e t h e s p r i n g
o n a l e v e ls u r f a c ea n d m e a s u r ei t
w i t h a s c a l e o r v e r n i e rc a l i p e r a s
s h o w n i n F i g u r e2 6 .
T h e l o w e r l i m i t i s 3 . 5m m .
N o t e : F o r l h e s e p u r p o s e s t, h e
sealstrokeis the sameas the free
( 1 )J o u r n a l .
M a k ea v i s u a li n s p e c t i o nf o r
s c r a t c h e sn, i c k s ,s c u f f i n go r
a n y o t h e r a b n o r m a sl i g n s o f
damage.
( 2 )O i l g a l l e r y .
C h e c kt h e o i l g a l l e r yf o r m e t a l
c h i p s ,p a r t i c l e so r a n y o t h e r
c o n t a m i n a n t s a, n d b l o w i t
c l e a rw i t ha i r .
( 3 ) B l i n dp l u g .
C h e c kt o m a k es u r ei t i s t i g h t ,
a s a l o o s ep l u g w i l l a l l o wo i l
leakage.
( 4 ) N e e d l eb e a r i n g .
C h e c kt h e n e e d l eb e a r i n gb y
i n s e r t i n gi t s m a t c h i n gt r a n s m i s s i o ni n p u t s h a f t a n d n o t i n gt h ef i t .
Lookfor anydamageto the oil
seal.
2' Measurement.
(1)Measuremen
o tf t h e e c c e n t r i c
s h a f tj o u r n adl i a m e t e r .
On each journal, measure
a c r o s si t i n t w o d i r e c t i o n sX,
and Y, as shownin Figure27.
M e a s u r ee a c h j o u r n a li n t h i s
w a y a t f o u r p o i n t sa l o n g i t s
a x i s .J u d g et h e s h a f t ' sc o n d i t i o n b y a n y s i g n so f a b n o r m a l
w e a r o r e x c e s s i v eo i l c l e a r ance.
ENGINE
Tightening torques, in kg-m.
ITEM
TORQUE
3.5
10-12
T e n s i o nb o l t s
D r i v ep u l l e y
Figure27
(2) Measuring
run-out.
T h i sm e a s u r e m e w
n ti l l r e q u i r e
V - b l o c k sa, d i a l i n d i c a t o a
r nd
standand a flat surface.Meas u r ea s s h o w ni n F i g u r e2 8 .
T h ea l l o w a b l e
l i m i tf o r r u n - o u t
is 0.'lmm. lf that limit is exceeded.the shaft must be replaced.
L o c k nu t ( c e n t e r w egi h t )
40-50
Flywheel
3.7-5.5
F r o n tc o v e r
1.6-2.3
gear
Stationary
1.6-2.3
Oilpan
0.7-1.0
Waterpump
Watep
r u m pp u l l e y
1.6-2.3
0.7-1.0
regulator
Pressure
Sparkplug
3-4
1.2-1.8
l n t a k em a n i f o l d
1.6-2.3
Exhausm
t anifold
4.4.5.9 |
Pressure
olate
1.8-2.7
Vl. Checks and Adjustments
A. Fuelsystem.
1 . C a r b u r e t osr p e c i fi c a t i o n s .
i,
I
I
Figure28
V. AssemblyOperations.
( 1 ) Due to its effect on engine performance,the fuel level should
be checked regularly.
(2) A d j u s t m e n tp r o c e d u r e .
The fuel levelshould be checked while the engineis idlingA t t a c h a s e c t i o no f c l e a r n e o p r e n et u b i n g t o t h e d r a i n p l u g
h o l e ,a n d r e a d t h e l e v e lw i t h a
s c a l ea s s h o w n i n F i g u r e2 9 .
A. Engineassembly.
The assemblyprocedurefor the
r a c e e n g i n ei s , f o r a l l p r a c t i c a l
p u r p o s e s t, h e s a m e a s f o r l h e
s t o c k e n g i n e .H o w e v e r r, e m e m berto be awareof any uniqueproc e d u r e sr e q u i r e da s a r e s u l to f
differentoartsthan the stockversion.
B. Pointsto remember:
( 1 ) U s e e n g i n e " ' ooi ln a l l m o v i n g
p a r t sa n d s u r f a c e sd u r i n ga s semblyto avoidmetal-to-metal
contact.
(2) Usenew gaskets,O-ringsand
lock washers with each re(3) Use two oil pan gaskets. One
g o e s o n t h e u p p e rs i d e o f t h e
b a f f l e p l a t e ,t h e o t h e r o n t h e
l o w e rs i d e .
Figure29
Clear neoprene
tubing
The allowable range for the
" A " d i m e n s i o ni s 2 1 - 2 3m m .
, ithl f a d j u s t m e n ti s r e q u i r e d e
er bend the float lever arm or
changethe numberof shims
o n t h e n e e d l ev a l v en i p p l e .
ENGINE
CheckList Of ClearancesAnd Tolerances
ITEM
V A L U E( m m )
DESCRIPTION
0.40-0.70
a
AR
M i n i m u mc l e a r a n c e r, o t o r t o r o t o r h o u s i n g
R o t o rh o u s i n gw i d t h - r o t o r w i d t h
(!
q)
U'
AH
H e i g h to f r o t o r l a n d
AG
AS
C l e a r a n c eb e t w e e na p e x s e a l a n d g r o o v e
R o t o rh o u s i n gw i d t h - a p e xs e a l l e n g t h
0.10 + 0.0'l
AC
betweencornersealandgroove
Clearance
0.02-0.048
AE
C l e a r a n c eb e t w e e nc o r n e rs e a l a n d s i d e s e a l
0.10+ 0.05
AF
c
(E
o
o
o
(r
o
o)
A p e xs e a l
o
Cornerseal
0.13-0.17
0.15-0.20
0.065+-0.005
Morethan3.5
'=
to
a
o
'=
(6
o
co
S i d es e a l
Stroke
morethan
Oilseal
0.5
l a x .d i a . )
Rotorbearing. A - ( B e a r i n gm i n .d i a . ) - ( J o u r n am
l in.dia.)
o i l c l e a r a n c e $ = ( B e a r i n gm a x .d i a . ) - ( J o u r n a m
0.07-0.10
l a x .d i a . )
A = ( B e a r i n gm i n .d i a . ) - ( J o u r n am
l i n .d i a . )
B = ( B e a r i n gm a x .d i a . ) - ( J o u r n am
0.05-0.08
Mainbearing
oil clearance
0.04-0.07
Endplay
o
o)
'6
Rotorhousing
S h r i n k a g e( b e t w e e nd i m e n s i o nA a n d B , C , o r D )
0.06
0.04
0.10
T = 2 O i( B T D C )
L=20" (BTDC)
Side
Surfacedistortion
I
housing
S i d e s e a l s t e p p e dw e a r
o
Timing
At idlespeed
o
l d l eR P M
o
o)
[U
V-belt
tension
1000-1500
RPM
D e fl e c t i o ne q u i d i s t a n tb e t w e e nw a t e r p u m p
and alternator
'10 -+ 1
q
_ E
o a
Tip clearance
2 . F u e lp u m p .
Both the fuel pump and relay
s h o u l db e m o u n t e di n r u b b e rt o
m i n i m i z ev i b r a t i o n sa,n d t h e f u e l
p u m p m u s t b e i n s t a l l e du P r i g h t ,
i n a v e r t i c a pl o s i t i o nt,o f u n c t i o n
p r o p e r l yT. h e f u e l l i n e s h o u l db e
7 - Bm m i n s i d ed i a m e t e ra, r r a n g e d
t o b e a s s h o r t a s p o s s i b l ea n d
r o u t e dt o a v o i da n yh i g ht e m p e r a t u r ea r e a s i;f r u b b e rh o s ei s u s e d
f o r l i n e s ,u s e o n l y m i n e r a l - p r o o f
r u b b e rF. i n a l l yd, o n o to p e r a t et h e
p u m pw i t h o u tf u e l i n t h e t a n k a s
i t m a ys h o r t e nt h ep u m pl i f e .
N o t e :T h ef u e l f l o w s h o u l db e 1 . 5
liters per 30 seconds,measured
22
L
0.07-0.10
-
l
a t t h e c a r b u r e t o cr o n n e c t i o n .
3 . F u e lf i l t e r .
Use care to installit for the corr e c tf l o w d i r e c t i o n .
4 . l d l es p e e d .
The idle speed should be set as
low as possible to avoid back firing.
5 . F u e lr e q u i r e m e n t .
The minimum oclane requirement
is 90. To provide sufficient lubrication for internal parts, the fuel
musl be mixed with the correct
e n g i n eo i l i n a r a t i o ,o i l - t o - f u e lo, f
1 : 1 0 0 - 1 : 1 5m
0 ,e a s u r e db y v o l u m e .
ENGINE
3 . H i g ht e n s i o nw i r e s .
P a y p a r t i c u l a ra t t e n t i o nt o t h e
s n the
c o n n e c t i o nasn dt e r m i n a l o
h i g ht e n s i o nw i r e s .
4 . S p a r kp l u g s .
T h e r e c o m m e n d esdp a r kp l u g i s
N G KV - t y p e1, 1 . 5h e a tr a n g e .
Note:The correctsparkplug gap
i s 0 . 7 - r 0 . 1m m .
B. Lubrieationsystem.
1 . Engino
eil.
l il is
A l o w a s h c o n t e n tm
, i n e r ao
r e c o m m e n d ew
d i, t h a v i s c o s i t yo f
e i t h e r4 0 w t o r 1 0 w - 4 0T. h e o i l
levelshouldbe F 'r 5 mm.
2. O i l c o o l e r .
T h e o i l c o o l e ri s e a s i l yc l o g g e d
w i t h d e b r i st h r b w n u p f r o m t h e
t r a c ks u c ha s c h u n k so f t i r e r u b b e r o r s m a l ls t o n e s T
. o m a i n t a i n lgnition W ir ing
propercooling performance,
the
coremustbe cleanedperiodically.
C. Cooling system.
1 . L i k e t h e o i l c o o l e r ,t h e r a d i a t o r
c o r ei s e a s i l yc l o g g e dw i t h d e b r i s
s u c h a s c h u n k so f t i r e r u b b e ro r
s m a l l s t o n e s .T o m a i n t a i nc o o l ing performance,it should be
c l e a n e dr e g u l a r l y .
2. R a d i a t ohr o s ea n dc l a m p s .
T h e r ei s n o s p e c i f i cc o m p e t i t i o n
hoseandclamp,but to avoidprobl e m s u s e h i g h q u a l i t yp a r t sa n d
m a i n t a i nt h e mi n g o o dc o n d i t i o n .
3. Coolant.
W ed o n o t r e c o m m e nuds i n ga n t i lreeze.For racing engines,we
havefoundcleanwaterto be the
m o s ts u i t a b l ec o o l a n t .
T h e c o o l a n ts h o u l db e c h a n g e d
regularla
y n d d r a i n e di n t h e w i n ter to avoidf reezing.
4 . V - b e ltte n s i o n .
T h e V - b e l t e n s i o ns h o u l db e a d justedfor a deflection
of 9-11mm,
m d a s u r e de o u i - d i s t a nbt e t w e e n
t h ew a t e rp u m pa n da l t e r n a t o r .
D. Electricalsystem.
1. Distributor.
T h e d i s t r i b u t olre a dm a y b e c o n l n the
n e c t e dt o e i t h e rt e r m i n a o
ignotor. There is no advance
mechanism
w i t ht h i sd i s t r i b u t o r .
2. lgnitor.
T h ei g n i t o rs h o u l db e m o u n t e di n
an areaprotectedfrom heat,wat e r a n d v i b r a t i o nA. l l w i r i n gc o n n e c t i o n ss h o u l db e s e c u r e ,a n d
all wiringmustbe separatedf rom
highvoltagewiresby at least100
mm.
Connector Wire
Tracer
color
number
{
b l a c k / w h i t e l g n i t i o ns w i t c h
b l a c k / y e l l o w Startersolenoid
2
terminal
I
J
4
5
6
7
8
I
A
B
l g n i t i o nc o i l p o s i t i v e
terminal
black
Grounded
Not used
blue
yellow
Not used
y e l l o w / g r e e nNot used
red/white
Not used
white
Not used
black/red
D i s t r i b u t os ri g n a l i n g
Distributor
signaling
5 . l g n i t i o nt i m i n g .
The timing is set with the drive
p u l l e yn o t c h a n d t h e i n d i c a t o rp i n
on the fronl cover; the notches
a r e d e n o t e da s s h o w n i n t h e i l l u s t r a t i o nb e l o w :
The trailing and leading plugs
s h o u l d b o t h be set to fire al 20"
BTDC.
ENGINE
Vll. OperatingProcedures.
A. Due to the high noise of the rotary
engine, we recommend using a
muffler around the garage or Pit
area.
B . An air cleaner is an absolute neces'
sity at all times to avoid loss of
compression from dirt entering
the engine.
C. Startingand warmingup the engine.
B e f o r es t a r t i n gt h e e n g i n e ,a l w a Y s
c h e c k t h e e n g i n eo i l a n d c o o l a n l
. nd lookfor
a n d t h e V - b e l t e n s i o nA
anyloosepartsor fasteners.
1 . S t a r t i n gp r o c e d u r e .
Depressthe throttlePedala coup l e o f t i m e s t o s q u i r ts o m e f u e l
i n t ot h e i n t a k et,h e nc r a n kt h e e n g i n e w h i l e h o l d i n gt h e t h r o t t l e
a b o u t w o - t h i r ddso w n .
N o t e :O n c o l d d a Y s c, i r c u l a t et h e
e n g i n eo i l f o r a s h o r tt i m e b e f o r e
starting.
2. Warm-upprocedure.
( 1 ) F i r s tr e m o v et h e r a d i a t o cr a P ,
t h e ns t a r tt h e e n g i n el.m m e d i a t e l ya f t e rs t a r t i n gc, h e c kt h e
e n dr e l e a s ea l l a i r
o i l p r e s s u ra
the
bubblesbYbothsqueezing
waterhosebYhandand racing
t h e e n g i n ea c o u P l eo f t i m e s ,
the cap securethenre-tighten
ly.
(2\ T h e e n g i n es h o u l d b e w a r m e d
at an idle speed of 2000-2500
R P M ,p n t i l t h e o i l t e m P e r a t u r e
r e a c h e s7 0 ' C o r 1 6 0 "F .
(3) D u r i n g w a r m - u p , w a t c h f t , r
c o o l a n t a n d o i l l e a k s ,a n d b e
careful not to foul a spark
plug.
D. Driving practices.
1 . T h e m a x i m u m a l l o w a b l ee n g i n e
s p e e di s 9 0 0 0R P M .
2 . T e m p e r a t u r ea n d p r e s s u r er e c o n l '
m e n d a t i o n sa r e a s f o l l o w s :
Limit
Normal
95'C
Coolanttemperature 70-90'c
( 1 6 0 - 1 9 5 ' F )(205'F)
(outletside)
Oiltemperature
(oilpan)
Oil pressure
(filterinlet)
24
W h e n t h e o i l o r c o o l a n tt e m p e r a '
tures exceed the limits, watch
c a r e f u l l ya n d c h e c k t h e s Y s t e mt o
determinethe cause. lf the oil
pressure falls below the lower
l i m i t , s t o p t h e e n g i n ei m m e d i a t e '
ly and determinethe cause before
proceeding.
E. Engine treatment after being run.
1 . P o u ra s m a l la m o u n to f e n g i n eo i l
t h r o u g ht h e c a r b u r e t o rt o P r e v e n t
i n t e r n a lr u s t .
2 . D u r i n gt h e w i n t e r ,d r a i n t h e c o o l '
antcompletely.
F. Overhaul schedule.
Startingwith a fresh engine,the over'
h a u l s c h e d u l e sa r e b a s e d o n e n g i n e
r e v l i m i t s u s e d d u r i n g r a c i n g ,a s f o l '
lows:
W i t h a r e vl i m i t o f :
R e b u i l da f t e r :
RPM
9OOO
km.
2000-3000
(1300-1900
mi.)
8 5 O OR P M
4000km.
(2500mi.)
G. Compressioncheck Procedure.
Use the rotaryengine cgmpression
tester, part number 49 0820 280K. A
n o r m a l c o m p r e s s i o nt e s t e r w i l l n o t
give a readingon the conditionof
l o r k i n gc h a m b e r .
e a c h i n d i v i d u aw
1 . P r i o rt o m e a s u r e m e n t :
( 1 ) W a r mu P t h e e n g i n e .
(2) Removethe trailingspark plug.
(3) Screw the comPressiontester
f i t t i n gi n t o t h e s P a r kP l u gh o l e .
( 4 ) D i s c o n n e c t h e i g n i t i o na t t h e
ignitor.
2 . M e a s u r e m e nPt r o c e d u r e .
( 1 ) T h e c o m P r e s s i o nt e s t e r o P e r a t e s o n 1 2v o l t s .
(2) To prclperlywarm uP the trac'
ing needle the comPression
testermust be turnedon five
(5)seconds Priorto oPeration.
(3) Crank the engine with the
t h r o t t l ew i d e o P e n f o r 1 0 s e c '
onos.
9 0 - 11 0" C
( 1 9 5 - 2 3 0F" )
1 2 0 c'
(250" F)
(4) Turn off the Powerto the com'
pressiontester.
5.5-7.5kg/cm'
0 kg/cm'
(5) Recordthe comPressionread'
in g s .
L't{slNE
nf condition.
3. Determinatioo
l f t h e c o m p r e s s i o np r e s s u r e f o r
any chamberis below 5 kg/cm2,
w i t h a c r a n k i n ge n g i n e s p e e d o f
2 5 0 - 3 0 0R P M , t h e e n g i n e s h o u l d
be rebuilt.
Overall maintenance of the racing
car.
We recommend keeping thorough
records on the maintenance performed on the car, along with all
p r a c t i c ea n d r a c e i n f o r m a t i o nT. h e s e
are two examples of the types of
recordforms we suggest:
T I M I N GS H E E T
LAP
R P M P o w e r( P S )
N e w b e a r i n g s Usedbearings
1500
2000
2500
24-30
3000
28.35
4000
47-57
0.5
1.0
5000
6000
63-77
1.0
94-108
1.5
0.5
0.5
0.5
12-14
16-19
6500 102-117
TOTAL
0.5
n <
0.5
0.5
1 6
0.5
7.0
z.J
RACE-
DRIVER T I M E
REMARKS
Notes on break-in:
( 1 ) T h e e n g i n eo i l s h o u l db e a l o w
ash content, mineral racing
oil.
(2) The water and oil temperat u r e s s h o u l d b e m a i n t a i n e di n
the range of 70-80' C (160175" F).
( 3 )T h e i g n i t i o nt i m i n g f o r b o t h
leading and trailing spark
p l u g s s h o u l db e 2 0 ' B T D C .
(4) The fuel should be a mixture
o f o i l - t o - u n l e a d e gd a s o l i n eo f
1 : 1 0 0 - 1 : 1 5m
0 ,e a s u r e db y v o l ume.
2. lf the engineis broken-inon a race
track:
M A I N T E N A N CS
EH E E T
DATE
Time(hours)
RACE
REMARKS
RPM
:;l
5000
6000
7000
8000
8500
,l
il'
':
j.r;
TOTAL
lr
Mileage
Newbearings
U s e db e a r i n g s
60
60
60
60
25
25
60
25
300
100
25
l:i
:i
;iJ
ri
:.t
.i.1
l,f.
REPLACEDPARTS
1
2.
3.
tli
'.ii
r,;i
..,1
tll
!1
L
ii
t]i
l!i
l.
New engine break-in.
The break-inprocedurefor a race engineis as follows:
1. lf a dynamometer
break-in:
used for
25
-,. ,, gua!
CHASSIS/DRIVELINE
l. Explanationand Descriptionof
CompetitionParts.
A. Clutch components.
1 . C l u t c hc o v e r , 4 3 51264 1 0
Toeliminate
c l u t c hs l i p p a g et,h i s
clutch has a boss-typedrive instead of the straight-typedrive,
and the working pressure has
been increasedfrom 380 kg to
6 3 0 k g . A d d i t i o n a l l y i,t h a s a
chrome-plated
releasecollar bearing.
2. C l u t c hd i s c , 4 3 5 2
1 64 6 0
Thisclutchhasa solidcentersection withoutany shockabsorbing
s p r i n g sT
. h e f r i c t i o nm a t e r i a li s
V-782-J,specially selected for
fade resistance,and the boss
s p l i n ei s c h r o m ep l a t e d .
3. Clutchmastercylinder.
Thisis the sameas the stockpart,
b u t d u et o t h e s i z eo f l h e v a c u u m
assist diaphragmfor the brakes,
t h e c l u t c h m a s t e rc y l i n d e rm u s t
be relocatedfor clearance.
4. Clutchreleasecylinder,
435241920
This is an adjustablereleasecyli n d e rw i t h a p i s t o n d i a m e t e ro f
11 / 1 6 " .
B. Transmlssion.
Thesearethe gearratiosof the stock
five-speed
transmissioncomparedto
the competitionversion:
1 s t 2nd 3rd 4 t h
5rh
Rev.
Competition
2.350 1.608 1.2401.000).881 0.839 2.26
Stock
3.6742.2171.4321.000 0.825 3.54
C o m p e t i t i otnr a n s :
(0.839)
4352-03-000
(0.881)
8570-03-000
l . T r a n s m i s s i ocna s e , 4 3 5 2 1170 0 A
T h i s c a s ei s c a s t a l u m i n u mw i t h
sections1.4 mm thicker than
stock(upfrom4.6mm to 6.0mm),
for increasedstrength,and it has
a startermotorbracketto support
the starteron both the front and
rearends.
2. Extension
housing,435217331
A s w i t h t h e t r a n s m i s s i o nc a s e ,
t h e e x t e n s i o nh o u s i n g i s a l s o
t h i c k e rt h r o u g ht h e s e c t i o n sT. h e
speedometergear and back-up
s a v eb e e ne l i m l a m pp r o v i s i o n h
lL
i n a t e d ,a n d t h e e n d b e a r i n gi s a
n e e d l er o l l e ri n s t e a do f t h e s t o c k
brushing.
3. Transmission
mount,4352-39-340
Comparedto the stock version,
t h i s m o u n ti s m a d eo f h a r d e r u b ber.
4. Maindrivegear,435217201
T h e c o m p e t i t i o nm a i n d r i v eg e a r
h a sa c h r o m ep l a t e ds p l i n ef o r i n creasedwearresistance.
5. Synchronizer
ring,435217245
T o i n c r e a s er i g i d i t y t, h e s y n c h r o
c o n ed i a m e t ehr a s b e e nc h a n g e d
for 1st, 2nd, 3rd and 4th gears,
from the 63 mm of the stock ver.
s i o nt o 6 2 m m .a s s h o w ni n t h e i l lustration.
Conediameler ( d i m e n s i o nA )
Competition
62 mm
Stock
63 mm
6. Synchronizer
key and key spring,
key:435217 243
spring:435217244
The increasedworkingpreloadof
thesepartsimprovesthe synchro
action.Thesepartsare applicable
to 1st-2ndand 3rd-4thgearsonly.
ForSth-reverse,
the key and spring
are the same as stock. The key
dimensionsare givenin the illust r a t i o nb e l o w :
Groovedepth
Comp.parts:0.7
mm
Stockparts:1.5mm
7. Gear bearings.
Needle roller bearings are used
o n 1 s t , 2 n d , 3 r da n d 5 t h g e a r s .
8 . S h i f t i n gf o r k s ,
1st-2nd:4352174O2
3rd-4th:4352174O4
Sth-Rev:435217 406
CHASSIS/DRIVELINE
The 1st-2ndand 3rd-4thshifting
forksareheavierand heattreated
for strengthand improvedshifting action.The 5th-reverse
fork is
heattreatedonly.
r s s e m b l y , 4 3 51275 1 0
9 . S h i f tl e v e a
T h i s i s a o n e - i n s t e a do f a t w o p i e c el e v e rw
, i t ha l a r g e d
r iameter
t h a nt h es t a n d a r d
version.
C. Drlveshaft.
1 . D r i v e s h a af ts s e m b l y , 4 3 5225 1 0 0
T h i s i s a s p e c i a tl w o - p i e c e
drives h a f tw i t h a c e n t e ru n i v e r s aj ol i n t
a n d s u p p o r tb e a r i n gl.t h a s b e e n
d e s i g n e dt o m o v e t h e r e s o n a n t
frequency
out of the workingrange
o f d r i v e s h a fstp e e d l. t s s p e c i f i c a tionsand configuration
areshown
[8re
3,
U
n
ro
(o
395
ll
f' t
573
T h i s h i g h e rc a p a c i t yb e a r i n gw i l l
a c c e p t t h e i n c r e a s e dd r i v e a n d
t o r q u el o a d so f c o m p e t i t i o nb, u t
m u s tb e u s e dw i t h t h e d i f f e r e n t i a l
carrierassembly
mentioned
above.
E. Rearaxle.
1 . A x l eh o u s i n ga s s e m b l y ,
435226020
T h i s a x l e h o u s i n gh a s b e e n d e s i g n e dt o w o r k w i t h t h e f a c t o r y
reardisc brakes,and has a baffle
plateto retainoil aroundthe gears
w h e nc o r n e r i n g .
2 . A x l es h a ft a s s e m b l y4,3 5 22 6 1 1 0
T h i s a x l es h a f ti s d e s i g n e dt o b e
used with the reardisc brakearr a n g e m e nat ,n d i t i n c l u d e sa l a r g e r c a p a c i t yb e a r i n g .l t i s f u l l y
c o m p a t i b l ew i t h t h e c o m p e t i t i o n
l i m i t e ds l i p u n i t ,b u t i f u s e dw i t h
t h e l i m i t e ds l i pw h i c hi s a v a i l a b l e
t o f i t t h e s t o c kv e r s i o no f t h e a x l e
h o u s i n gt,h e a x l em u s t b e c u t o f f
b y 5 m m o n t h e s p l i n e de n d t o
avoidinterference.
Notes on Machining and Assem.
blv.
N o t e :A l l d i m e n s i o n sa r e i n m m .
D. Dlfferential.
1 . D i f f e r e n t i agl e a r s a r e a v a i l a b l ei n
t h e f o l l o w i n gr a t i o s :
Ratio
4.111
4.375
4.444
4.625
4.875
T e e t h( r i n g / p i n i o n ) P a r t N u m b e r
37t9
35/8
40t9
37t8
39/8
1013-27-110
0839-79-950
1393-27-110A
0881-79.720
1312-27-1104
L i m i t e ds l i pd i f f e r e n t i a l ,
0820799608
Thelimitedslip is a frictionclutch
t y p ef o rs i m p l i c i t ya n de ff i c i e n c y .
D i ff e r e n t i acl a r r i ear s s e m b l y ,
435227150
T h i sc a r r i e ar s s e m b l iys d e s i g n e d
e x c l u s i v e l tyo w o r k w i t h t h e i n creased load capacity bearing
a l s o a v a i l a b l ea s a c o m p e t i t i o n
part.
Rearbearing,0540
27 141
A. Clutch.
1. A stop blockto limit clutch pedal
travel must be fabricated and installed on the floorboardas shown
i n t h e i l l u s t r a t i o n .W i t h o u t t h e
stop block,excessiveclutch pedal
travel will push the clutch diaphragm spring over center,resulti n g i n t h e c l u t c h h a n g i n gu p a n d
n o t r e - e n g a g i n gw i t h h i g h s p e e d
g e a r c h a n g e s . A d d i t i o n a l l y ,t h i s
excessivepedal travel will cause
distortionof the diaphragmspring.
II
CHASSIS/DRIVELINE
2 . T h e i l l u s t r a t i o nd e p i c t s l u b r i c a t i o n p o i n t si n t h e c l u t c hm e c h a n i s ma s s e m b l y .
key
3. The end of the synchronizer
s p r i n gs h o u l db e g r o u n do f f s o a s
t o e l i m i n a t ea n y c h a n c eo f c o n tactwith the clutchhub,as shown
C l u t c hh u b
B. Transmlsslon.
1 . S h i f tl e v e r .
The shift levercan be heatedand
bent to suit the driver's Preferwe havefoundit
ence.Generally,
s h o u l d b e i n c l i n e dt o w a r d t h e
driverby about 20' as shown in
t h ei l l u s t r a t i o n .
4 . T h e s h i f t i n gf o r k b o l t ss h o u l db e
secured with both Loctite and
safetywire to thoroughlyprevent
as shown
anychanceof loosening,
L o c t i t eH e r e
5 . T h e c o n f i g u r a t i o nfso r t h e b u s h eears
i n g sf o r 1 s t , S t ha n dr e v e r s g
are shownbelow.Usecareto as, ith the
s e m b l et h e m p r o p e r l yw
correctgears.
gear
Forreverse
F o rf i r s tg e a r
2. Therubbershift leverbootshould
be tiedtight aroundthe leverwith
wire to preventoil leakageinto
t h e c o c k p i ta, s s h o w ni n t h e i l l u s tration.
Forfifthgear
29
CHASSIS/DRIVELINE
b) The bracketshouldbe weld'
ed to the undersideof the
floor Pan as shown in the
i l l u s t r a t i obne l o w '
mount'
6. The rubbertransmission
a
s
s
e
m
b l e di n
i n o u r o c xm u s t b e
illust
h
e
i
n
s
h
o
w
n
inE Oitection
tration.
Holes for T/M's installation
Front \
c.
Dlfferentlal.
tht;adedPortionof the breath;:'ih;
er is too long,so to Preventinter'
ferenceit must eitherbe assem'
bled with a 6 mm spacernut' as
s h o w no, r c u t b Y5 m m '
D. Drlveshaft.
1. Centerbearingsupportbrackets'
is for
{1)
' ' The followingProcedure
the left sidebracket'
a)' Fabricatethe left bracket
for the centerbearingsuPPortaccordingto.the illus'
iration.The materialis steel
the
P l a t e1, . 4m m t h i c k ,a n d
1
'
2
5
'
P
M
1
0
,
b o l ti s
Bracket'sbolt center
To
lr)
r0o
is for
(2\ ThefollowingProcedure
bracket'
side
the rioht
at-fairicate the right bracket
f o r t h e c e n t e rb e a r i n gs u P '
o o r t a s s h o w ni n t h e i l l u s '
lration.The materialis steel
olate,1.4mm thick,andthe
b o t ti s M 1 0P 1 . 2 5 .
b) Weldthe bracketto the undersideof the f loor Panaccording to these instruct i o n sa n dt h e i l l u s t r a t i o n '
' The engine, transmission
and re-ar axle must be
iounted, and the lett side
bearinq suPPort bracket
mustie weldedin Place'
' Assembte the centerbear'
inq suPlort to the drive'
sialt, and then mount the
driveshaftto the car, athching the bearing s.uP'
porttithe tettside bracket'
' With everYthingbolted uP
in Place,mark the location
on theftoorPan for the right
side bracketbottrelief hole'
' Cut a 30 mm diameterhole
tni" tocation' With the
oi
-Oiraciet
in Place, there will
be a clearancearound the
Lott neaA,and so the hole
shoutdbe exactlYon cen'
ter.
'Wetd
'
the bracket to the
tloorPan.
CHASSIS/DRIVELINE
Note: After attachingthe center
supportbearing,checkand make
certainthe driveshaftis straight
and true. lt is recommendedto
checkfor driveshaftstraightness
beforefinalweldingon the brackets. One suggestedmethod to
check for straightnessis to tie
w e i g h t e ds t r i n g st o t h e t r a n s m i s s i o n e x t e n s i o nh o u s i n g ,c e n t e r
b e a r i n ga n d d i f f e r e n t i acl o m p a n i o n f l a n g e t, h e nv i s u a l l yn o t et h e
alignmentfrom the rear; make
c e r t a i na l l t h e s t r i n g sh a n g f r o m
the exact centers of the three
locations.
2. The floor pan of the car must be
p o u n d e do u t a s s h o w ni n t h e i l lustrationfor relief around the
centerbearingsupport.
2. Freeplay.
Thefreeplaysettingsare:
Between master cylinder
p u s h r o d : 0 .-5r 0 . 2 5m m .
Between release cylinder arid
p u s h r o d : 1 .+5 0 . 5 m m .
3 . W h e na s s e m b l i ntgh ec l u t c hd i s c ,
u s ee i t h e rt h e t r a n s m i s s i oinn p u t
s h a f to r a c l u t c h a l i g n m e n t o o l
t o a l i g nt h ed i s cp r o p e r l y .
4. The clutch release fork return
s p r i n gs h o u l db e m o u n t e di n s i d e
a rubbertube to preventthe occurrenco
e f r e s o n a nvt i b r a t i o n s .
B. Transmlsslon.
1 . G e a ro i l .
G e n e r a l l y , 9w0t g e a ro i l i s r e c o m mended for most conditions.
However,if the ambienttemperature is over85o F, a heavierlubric a n ts h o u l db e u s e d .
break-in.
2. Transmission
i n a n e wt r a n s m i s W h i l eb r e a k i n g
r t t e n t i o nt o
s i o n ,p a y p a r t i c u l aa
a n y l e a k s ,a b n o r m a ls o u n d so r
u n u s u a lv i b r a t i o n sT. h e b r e a k - i n
i s a s s h o w ni n t h et a b l e .
schedule
E n g i n er e vl i m i t s
E. Rearaxle.
1 . T h e r e a ra x l es h o u l db e m o u n t e d
w i t h t h e l e n g t ho f t h e l o w e rc o n trol linksset to 495mm from center-to-center
of the rod ends, so
t h e n o s eo f t h e d i f f e r e n t i ai ls i n c l i n e du p w a r d sb y 2 " , a s s h o w n
lll. Checks,Adjustments and Practices.
A. Clutch.
1. Pedalstroke.
The pedalstrokeshouldbe set at
130 'r 5 mm, by adjustingthe
pedal strokestop block and the
pedalreturnstop.
6000
7000
8000
TOTAL
Mileage
15
15
15
45
C. Driveshaft.
1 . T h e c o m p e t i t i o nd r i v e s h a f th a s
alreadybeenbalancedas a comp l e t ea s s e m b l yl .f d i s a s s e m b l i n g ,
it in the
use care to re-assemble
correctorderto maintainits bala n c e .F i n a l l yt,h e f o r w a r ds e c t i o n
s h o u l dn o t b e d i s a s s e m b l e da,s
on that end could
an unbalance
lead to metal fatigueand cracki n go f t h e t r a n s m i s s i oenx t e n s i o n
housing.
2. Make certainthere is a balance
weight on the driveshaftbefore
u s i n gi t .
3. Checkthe universaljoints accordi n g t o t h e f o l l o w i n gd i r e c t i o n s
a n dt h ei l l u s t r a t i obne l o w .
(1) The correcttorqueshouldbe
3-Bkg-cm(witha newjoint).
(2) To check the forwarduniversal joint, attach the sliding
scaleto theyoke.
CHASSIS/DRIVELINE
To check the rear universal
i o i n t ,a t t a c ht h e s l i d i n gs c a l e
i o t h ef l a n g eb o l th o l e .
(4) To checkihe centeruniversal
ioint,hang the driveshaftver'
iicariv tro-mtne forward end
a n O i t t a c n t h e s l i d i n gs c a l e
with a wire aroundthe drives h a f t ,1 0 0m m f r o mt h e c e n t e r
o f t n i j o i n t , a s s h o w ni n t h e
illustration.
<-l F ro n t
0.8-2.0kg
D. Differentlal.
1. Break'in.
A newdifferentialmustbe broken
i n b e f o r eu s i n g i n c o m P e t i t i o n '
This can be donein a standard
car,andthe Procedure
Passenger
i s a sf o l l o w s :
Forthis at or
OPerate
n
u m b eo
rf
t
h
i
s
below
kilometers:
speed:
60km/h(40mi/h) 100km (ggtil
B0km/h(somffir) 100km (gqlni).
kmt]fQm!)
roolmrnioo
' min) 2oo
km (240mi)
4@
Total:
D u et o t h e i n i t i a lP r e l o a do n t h e
gear, lack of a Proper
oinion
'break-in-will
result in an exces'
o
i l t e m P e r a t u raen d
h
i
g
h
iiuefy
scoringof the gearteeth'
2. Lubricant.
The Proper lubricant is 90 wt
hYPoidgear oil' The amount re'
qlireOf6r sufficientlubricationis
tem'
2.0liters'Whenthe ambient
' F' us.ea
85
above
is
Perature
hign"t viscositylubricalion^than
90 wt'
th6 normallY-recommended
3. Preload.
( 1 ) W i t h a n e w P i n i o nb e a r i n gt h e
P r e l o a ds h o u l db e 9 ' 1 4K g ' c m '
After break'in,the Proper Prekg-cm'
l o a di s 2 . 3 - 3 . 5
(' 2' ) l f u s i n g a u s e d b e a r i n g ' t h e
Preload should be the same
as it was before disassembling
t h e d i f f e r e n t i a ll-f i t i s n o t P o s '
sible to achieve that, rePlace
t h e d i s t a n c eP i e c e '
4. When exchanging the ring ancl.
o i n i o n ,u s e L o c t i t eo n t h e b a c Ko I
lne rin'ggear and bolts' The tight'
ening t-orqueis 6.5'7'5kg'm'
5. Breather.
According to the layout of the.par'
ticular race course,there are three
oositions for the rear axle breath'
br. "t shown in the illustration'
F o re x a m P l e :
(1) On a coursewith PredominanllY lelt hand turns, use Posltlons 1 andZand block off 3'
(2) On a course with Predominant'
lv rioht hand turns, use Posl'
tioni Z and 3 and block off 1'
E. Rearaxle.
Checkthe axlebearingand the beari n g c o l l a r .l f t h e c l e a r a n c eb e t w e e n
t h e b e a r i n ga n d t h e c o l l a r i s m o r e
t h a n1 . 0m m ,r e p l a c et h ea x l es h a f t .
Check List For DrivelineComponents
1. Clutch.
ITEM
Clutchpedalf reeplay(untilpushrodcontactspiston)
Clutchpedalf reeplay(untilreleaseforkbeginsto move)
U s a b l ec l u t c h d i s c t h i c k n e s s( d e p t ha t r i v e th o l e )
f luidlevel
Reservoir
Releasefork f reeplay(betweenforkand pushrod)
A P P R O P R I A TV
EA L U E
1-3mm
5 - 1 3m m
0 . 3m m
f i l l t o m a x .l e v e l
1-2mm
Tightening torgues.
TOROUE
C l u t c hc o v e r
1 . 8 - 2 . k7g - m
C l u t c hh o u s i n g
3.8-5.3kg-m
2. Transmission.
M a i ns h a ft r u n o u t
ringandgear
betweensynchronizer
Clearance
quantityrequired
Lubricant
type
Lubricant
S A E9 0 w t . h y p o i dg e a ro i l
Tightening torques.
TORQUE
ITEM
Mainshaftlocknut
locknut
Countershaft
kg-m
13.0-21.0
S h i f t i n gf o r k ( 1- 2 ,3 - 4 )
1 . 2 - 1 .k7g - m
1 2 . 0 - 1 6 .k0g - m
S h i f t i n gl o r k ( 5 - R )
1 . 2 - 1 . 6k g - m
Case
1 . 2 - 1 .k4g - m
Lockballcap
1 . 0 - 1 .k5g - m
33
CHASSIS/DRIVELINE
3. Driveshaft.
ITEM
runoul
Driveshaft
jointresistance
torque
to movement
Universal
VALUE
APPROPRIATE
l e s s t h a n 0 . 4m m
3-8kg-cm
Tightening torques
ronout
C o m p a n i o nf l a n g e
4.
kg-m
3.5-3.8
kg-m
3.7-5.5
Differential.
ITEM
APPROPRIATV
EALUE
P i n i o nb e a r i n gp r e l o a d( n e w )
9 - 1 4k g - c m
S i d eb e a r i n gp r e l o a d( n e w )
6-2'lkg-cm
Bearingcappilotmeasuremenl
R i n o a n d o i n i o nb a c k l a s h
B a c k l a s h .m a x i m u ma l l o w a b l ev a r i a t i o n
quantityrequired
Lubricant
R e c o m m e n d e dl u b r i c a n t ,v i s c o s i t y& t y p e
Ringgearrunout
Spacer(foradjustingpiniongearposition)
+ 0
185.5- 0.075mm
0 . 1 7 - 0 . 1m9 m
0.07mm
2.0liters
SAE 90 wt. hyPoid
0.05mm
14spacershimsareavailable,
of 0.03mm,from
in increments
mm thick
3.08-3.47
Tightening torques.
ITEM
D r i v ep i n i o nn u t
R i n gg e a r( u s eL o c t i t eo n b a c k o f r i n g g e a r )
S i d eb e a r i n gc a p
TORQUE
kg-m
13.0-18.0
12T6.5-7.5kg-rn
12Tf lange,7.5-8.5kg-m
3.8-5.3kg-m
'J
r
r.,
.. L!vl
CHASSIS/BRAKESYSTEM
Specifications
Item
Comp.spec.
Category
Footbrake
P e d a lr a t i o
conlrolparts
P c w e ra s s i s t d i a p h r a g md i a m e t e r
4.77
7.5"
1 5 / 1 6&" 1 "
M a s t e rc y l i n d e rd i a m e t e r
Frontbrake
Type
v e n t i l a t e dd i s c
R o t o rt h i c k n e s s
Caliper
Effective
radius
Friction
pad
Rearbrake
Stock spec.
4.77
o.u
13/16"
s o l i dd i s c .
25mm
18mm
type
opposed
fl o a t i n g
c y l .d i a .
2.1t8"
'102mm
2.0"
9.7
90mm
F-50
9.0
s o l i dd i s c
drum
ss-100.
ss-123
material
thickness
Type
Rotorthickness
10mm
N/A
Cylinder
diameter
radius
Effective
1-3/8"
11 / 1 6 "
Friction
pad
93 mm
ss-123
ss.100,
material
thickness
9.0
J-6020-C
4.0
30-100
kg/cm'
P r o p o r t i o n i n gv a l v e
l i n e p r e s s u r er a n g e
i n d e rd u et o t h e i n c r e a s e sdi z eo t
the power assist vacuum diaphragm.
l. Explanationand Description of
CompetitionParts.
A. Foot brakecontrol systom.
C o m p a r etdo t h es t o c ku n i t ,t h ec o m petition assemblyhas greaterefficiencythrougha largerservoassist
vacuumdiaphragmanda largermast e rc y l i n d edr i a m e t e r .
1. Powerassist,for right-hand
drive:
435249 800
for left-hand
drive:435243 800
As a resultof increasingthe assist vacuumdiaphragmfrom 6.0"
t o 7 . 5 " i n d i a m e t e r t, h e c l u t c h
mastercylindermust be moved
2 5m m t o t h e l e f t .
2. Mastercylinders,
1":435249400
15/16":435243400
Two mastercylindersare availab l e t o s u i t i n d i v i d u apl r e f e r e n c e s
anddrivingstyles.
3. Mastercylinderbracket,
435243 160
This bracketis used to facilitate
r e m o u n t i ntgh e c l u t c hm a s t e rc y l -
1 0 0m m
B. Front brake.
1. Rotor,435233251
T h i sr o t o ri s 2 5m m t h i c k ,c o m p a r e d t o t h e s t o c k t h i c k n e s so f 1 9
m m , a n d h a s a l a r g e re f f e c t i v e
r a d i u s1, 0 2m m i n s t e a do f 9 0m m .
2. Wheelhub,435233061
T h i sw h e e lh u b h a s a l a r g e rb e a r ing capacity and special rotor
a t t a c h m e nbto l t s .
3.
R:435233610
L:435233710
t o t h e s t o c k u n i t ,t h i s
Compared
c a l i p eh
r a so p p o s e dp i s t o n sl,a r g er cylindersand is assembledto
the steeringknuckleby two bolts.
4 . A i rd u c t ,
R : 4 3 5 23 32 6 0
L:435233270
T h i sd u c t p r o v i d e cs o o l i n ga i r f o r
the brakes.
35
CHASSIS/BRAKESYSTEM
5. FrictionPad,
33625
SS-100:4352
SS'123:435233 725
is a hardercomPound
The SS-100
racing;the SS'123
endurance
for
is intendedfor sPrintraces'
C. Rearbrakes.
1. Rotor,435226251
, i t ha n o u t e r
T h i si s a s o l i dr o t o r w
diameterof 254mm (10in),and is
1 0m m t h i c k .
2. CaliPer,
R:435226980
L: 435226990
Theseareslidingpin typecalipers
and includeProvisionfor a Park'
ing brake'TheYattachto th.eaxle
housingwith a mountingadaPl^oi'
andthe cylinderdiameteris 1'3/8"'
3. MountingadaPtor'
R:435226921
L: 435226931
These adaptorsare requiredto
mountthe rearbrakeassemblies
t o t h ea x l eh o u s i n g .
4. Reardust Plate'
R:435226260
L:43522627O
5. FrictionPad,SS'100;
inner:435249625
outer:435249725
T h i sv a l v ew i l l l i m i t t h e l i n e p r e s '
sureto the rearbrakes.The varia'
ble rangeis 30'100kg/cm' 'With
e a c hc l o c k w i s et u r no f t h e a d j u s t m e n t , t h e l i n e P r e s s u r ew i l l i n '
creasebY10kg/cm' .
valvehold'
7. Variableproportioning
er,887143 750
U s et h e s t r u tt i g h t e n i n gn u t t o a t '
t a c h t h i s h o l d e rt o t h e s t r u G t u r e
of the car.
ll. Machining OPerations.
A. Changingthe positionof the clurch
mastercYlinderDue to the largerPowerassist vac'
u u m d i a P h r a g mt ,h e c l u t c h m a s t e r
c y l i n d em
r u s tb e m o v e dt o t h el e f t '
1 . T h e P r o c e d u r ef o r m o v i n g t h e
clutch mastercYlinderis as fol'
lows:
(1)As shown in the illustration
below' locate and mark the
n e w m o u n t i n gh o l e s o n t h e
f i r e w a l l ,2 5 m m t o t h e l e f t
of the standardones'
(2) B l o c k o f f t h e o r i g i n a l h o l e s
w i t h a s u i t a b l es t e e l P l a t e .
(3) C u t a n d d r i l l t h e n e w h o l e s .
(4) A f t e r c o m P l e t i n gt h e i n s t a l l a '
tion, cover and seal anY holes
that would allow water into
t h e i n t e r i o ro f t h e c a r .
ss-123;
inner:435226625
outer:435226725
As with the frontPads,the SS'100
is for enduranceraces;the SS-123
is for sprintraces.
valve,
Variable
6.
ProPortioning
386343 900
Powerassist
I
I
I
I
\
\
"nf
\
L
t
{-
o\-/O
I
r l
o o10
I
/
j-e
32,1'
9?
- +l 'z -li;4
100
q,
o
o
o
o
o
o
t
o
30
30
I n p u to i l P r e s s u r e 1 0 0
2. Modificationto clutch pedal push'
rod.
With the change of the master
cylinder's location in the preceding operation,the push.rod'sp,osi'
tidn irvitthave to be changed as
s h o w ni n t h e i l l u s t r a t i o n .
SYSTEM
CHASSIS/BRAKE
lll. Checks,Adjustmentsand Maintenance.
A. Brakecontrol parts.
1. Adjust the stroke at the brake
pedal with a power assist valve
operatingrod,by turningthis rod
u n t i lt h ev a l v ep l u n g ehr a s5 - 7m m
of travel left before contacting
t h ev a l v ep l u n g esr t o p p e r .
2. The effective stroke at the brake
pedal should bq more than 143
mm. lf less than that, the brakes
will not retract adequately and
they could fade from the constant
heat.
3. The brakesshould be bled before
each race,even if the system has
been recentlyoverhauled.
4. Do not mix brakefluids,and use
o n l y f l u i d sw i t h a h i g h b o i l i n g
5. Avoid any water in the system.
Even2-3percentwaterin the f luid
w i l l l o w e rt h e b o i l i n gp o i n t s u f f i cientlyto causea significantdrop
i n e f f i c i e n c yA
. d d i t i o n a l l yi,t i s
to change
stronglyrecommended
the fluid beforeeach race meeting.
6. Two mastercylindersare availab l e a s c o m p e t i t i o np a r t s ; t h e
1 5 / 1 6 "d i a m e t e rv e r s i o ni s s t a n dard. For a harderpedal feel or
shorterstroke,the 1.0" cylinder
is an alternative.
B. Front brakes.
1 . U n d e rn o r m a lr a c i n gu s e t h e c o m p e t i t i o nr o t o r s w i l l l a s t f o r a b o u t
3 , 5 0 0m i l e s .T h e r o t o r s s h o u l d b e
kept free of rust or any of the black
c o r r o s i o nw h i c h r e d u c e s f r i c t i o n
betweenthe rotor and the pads.
2. Wheneverreplacingthe rotor,also
r e p l a c et h e b o l t s w h i c h s e c u r e i t
to thehub.
3. Undernormalracing use the wheel
bearings should last for about
3 , 5 0 0m i l e s . U s e m o l y b d e n u md i s u l f i d e g r e a s e ,a n d c h a n g e i t b e fore everyrace.
4 . T h e c o m p e t i t i o nc a l i p e r sa r e c o n sidered to be a semi-permanent
i t e m w i t h a n i n d e f i n i t el i f e s p a n .
However,they must be replaced
if overheating has deteriorated
t h e r p i s t o n s e a l s ,r e s u l t i n gi n i m proper or incomplete retraction
o f t h e p i s t o n si n t o t h e c a l i p e r .
5 . S h i m s a r e u s e d t o a c h i e v et h e r e q u i r e d e q u a l i z e dc l e a r a n c e ,s i d e to-side,betweenthe rotor and the
c a l i p e r .T h e s e s h i m s f i t b e t w e e n
t h e c a l i p e r a n d k n u c k l e ,a n d a r e
available in three thicknesses:
0.2,0.6 and 0.8 mm. The shims
c a n b e u s e d s i n g l yo r i n c o m b i n a tions to obtain a clearanceon
each side, measuredbetween the
mm.
r o t o ra n d t h e p a d s , o r 1 . 5 - 2 . 2
Thepartnumbersare:
0 . 2m m 0 8 1 33 36 1 7
0 . 6 m m 0 8 1 33 36 1 8
0 . 8m m 0 8 1 33 36 1 9
removingthe hubfrom
6. Whenever
t h e k n u c k l er,e p l a c et h e h u bc a p s
to preventdamageto the wheel
b e a r i n gt h a tc o u l dr e s u l tf r o mt h e
capcomingoff.
7. Thecompetitionbrakepadcan be
useduntilit is downto 1 mm thicktheseare the racness.Generally,
ing mileagesto be expectedfrom
t h ep a d s :
SS-100 morethan 1,000km
(600mi)
SS-123 lessthan 1,000km
(600mi)
8 . l t i s a l w a y sh i g h l yr e c o m m e n d e d
to break in new pads for a few
lapsbeforea race.
37
CHASSIS/BRAKESYSTEM
c.
Makecertainthe brakelines are
tooshortcould
iiil ti"".t length;
fail'
Rearbrakes.
""ui" oi."kagl and ultimate
uie of the sYstem,too lonq lo.ses
"tii"i"n"y, causesa softerfeeling
i; ih;;;d;1, and couldalsoresult
i n t n " ' l i n e r u b b i n ga g a i n s tl o T e
iotlting Partor wearingagainsta
roughedge.
can
1.
" The comPetitionbrakerotor to
down
worn
is
it
until
6f tt"O
9 . 0m m t h i c k .
an in'
2
-' . T h e b r a k ec a l i p e ri n c l u d e s is.a
i;;;"1 larking brake'There
;;i; Jn in" liston which,s!'toYtd
6e matchedexactlYto the friction
t1?1"
Pad.The Parkingbra.ke
l:
rotor' so
the
to
close
bositioned
it to
["r* .ate to routeor suPPort
dam'
avoidcontactand Possible
age.
for service
3. The recommendations
-'
brake
Pads
front
;;;'rite ot the
rear
the
to
Pads'
Itso aPPtY
Y?lvq
4.
" The variableproportioning.
" " n b e a d j u s t e di o s u i t i n d i v i d u a l
pieterencis.However'as.a starting Point,use the followingrecommendations:
D r yc o n d i t i o n s
Wetconditions
Gheck List for Brake SYstem
i fi c a t i o n
Item
6-7 mm
BrakePedalf reePlaV
254mm ('t0in)dia.x
Frontrotor
25mm thick
9.7mm (eff ectiveamount
F r i c t i o nP a d
8.7mm)
thickness
254mm (10in)dia.x
Rearrotor
10mm thick
9.0mm (effectiveamount
F r i c t i o nP a d
8.0mm)
thickness
Fillto upperline
Amountof brake
fl u i d
80 kg/cm
50-60kg/cm
Tightening Torques
D. Plumblngand llnes'
Item
t o r q u eo n t h e p i p e
1 . T h et i g h t e n i n g
k
n u t si s 1 . 3 ' 2 . 2g - m '
F r o n t r o t o ra n d h u b
2.
-' Forprotection,it is recommended
in"'brat<e hose be wound with
"oit", but be carefulnot to dam'
"g"-in" brakeline with the wire'
R e a rc a l i P e r
lincr
Rearrotor
Mortntino adaPtor
B r a k el i n e s
kg'm
Torque,
1.0-1.3
8-10
6.8-8.3
4-4.8
4-4.8
1.3-2.2
N
CHASSIS/STEEHING An r--i$ USiPEN$tlO
AND SUSPENSION
CHASSIS'STEERING
Specificatiorle
CategorY
tem
Steering
S t e e r i n gw h e e l
S t e e r i n gg e a r
Front
suspension
Rear
susPension
Comp.spec.
sameas stock
S t o c ks p e c .
14.5:1
17-2O:1
Remarks
3 8 0m m d i a .
-inkage
sameas stock
)oil spring
'ate
3 . 4k g / m m
1 . 9k g / m m
fr e el e n g t h ,
comp:252mm
s t o c k : 3 3 8m m
\ n t i - r o l lb a r
25mm dia.
23mm dia.
c o m p .l o c a t i o n :
1 =2.92i2 - 2.79;
3 = 2 . 6 5 ;4 = 2 . 5 3
jhock
lbsorber
Piston m a x . l e n g t h / t r a v e l ,
adjustable
Piston non-adlust.
comp:540/145
dia.
rod.20mm
r o d . 2 2m md i a .
stock:5961177
3umpstoP
(nucklearm
30mm ht.
reinforced
40mm ht.
)oilspring
ate
3.2kg/mm
2.0kg/mm
f reelength,
comp:278;stock:315
ihock
rbsorber
adiustable
non-adjustable
m a x .l e n g t h / t r a v e l ,
comp:5221168
stock:548/190
{nti-rollbar
1 9m m d i a .
1 . 5k g / m m
1 8m m d i a .
1 . 2k g / m m
lump stop
3 7 . 5m m h t .
5 2 . 5m m h t .
(2) Compared to the stock unit,
l. DescriPtionand ExPlanationof
ComPetitionParts
they have less travel.
(3) They are adjustable to allow
A. Steering.
1. Steeringgearbox.
for right-handdrive:4352BO030
for left-handdrive: 435232920
T h i s g e a r b o xh a s a q u i c k e r r a l i o
of 14.5:1.
B. FrontsusPension.
1. CoilsPring,435234011
To lowerthe car,reduceroll when
corneringand Pitch when brak'
ing,this is a shorter,stifferspring'
Tht designdetailsareas follows:
C o m p e t i t i o n Stock
W i r e d i a m e t e r( m m )
Freelength(mm)
Springrate(kg/mm)
12
12
252
338
3.4
1.9
2. StrutassemblY,
R:435234910
L:435234920
(1) The damPeningcharacteristics of theseshockshavebeen
selectedfor racingPurPoses.
f o r c h a s s i st u n i n g .
( 4 ) T h e k n u c k l es P i n d l ei s s t r o n g e r f o r i n c r e a s e dd u r a b i l i t Ya n d
safetY.
3. Bump stops, 435234111
To retain sufficient susPension
travelwith the loweredride height
o f t h e s h o r t e r s P r i n g s ,t h e b u m P
stops are shorter than stock bY
1 0m m .
4. Anti-rollbat,435234 151
T h e d e t a i l s o f t h i s l a r g e rb a r a r e
as follows:
Competition Stock
D i a m e t e r( m m ;
R a t e( k g / m m )
25
23
2.75
2.O
A d d i t i o n a l l Y ,t h i s b a r h a s f o u r
p o s i t i o n sf o r t h e c o n n e c t i n gl i n k ,
providing several combinations
o f s t i f f n e s sa n d a l l o w i n g e a s e o f
c h a s s i st u n i n g .
5. Lower arm assemblY,
R: 435234 300
L:435234 350
39
NG AND SUSPENSION
CHASSIS/STEERI
K n u c k l ea r m :
R:435232301
L: 435232311
T h e l i n k a g eu t i l i z e sa s P h e r i c a l
rod end insteadof rubberbushi n g s . A n d t h e ' k n u c k l ea r m i s
strongea
r n d h a s b e e nr e d e s i g n ed for clearancearoundthe wheel
a n dt i r e .
2 41 3 0
6 . T e n s i o nr o d , 4 3 5 3
Bracket,R:435234850
L:435234860
T o e l i m i n a t el o n g i t u d i n aclo m p l i l r mt h e
a n c eo f t h e l o w e rc o n t r o a
forward end of the tension rod
h a sa s p h e r i c arlo de n dj o i n t .
435234800
7 . Crossmember,
T h i si s t h e s a m ec o n f i g u r a t i oans
stock,but is stronger.
8 . A l i g n m e nst e t t i n g sf o r f r o n t s u s '
pension:
3. Rearanti-rollbar,435228 151
T h e s ea r et h ed e s i g nd e t a i l s :
Competition Stock
D i a m e t e r( m m )
R a t e( k g / m m )
19
18
1.5
1.2
4. Rearaxlecontrolarms,
28300
upper:4352
lower:435228200
The lowerarm has sPhericalrod
e n d si n s t e a do f r u b b e rb u s h i n g s .
The upperarm has rubberbushwhen
ingsto preventinterference
c o r n e r i n ga n d i s l o n g e r t h a n
stock.
CompetitionStock
247
413
L e n g t ho f u P P e rl i n k ( m m )
500
495
L e n g t ho f l o w e r l i n k ( m m )
C o m p e t i t i o n Stock
Camber
Caster
K i n gp i n i n c l i n a t i o n
T o e - i n( m m )
C a m b e ro f f s e t ( m m )
Castertrail (mm)
- 1' 3 0 '
+1
30
4"
14" 42'
1 0 "5 5
O-out0.5
84.2
3r3
38
14
19
C. Rearsuspension.
1. Coilspring,435228011
T h i s s p r i n gi s s h o r t e ra n d s t i f f e r
than stock;theseare t h e d e s i g n
details:
Wirediameter(mm)
CompetitionS t o c k
m i d d l e ,11 . 2 10.2
b o t he n d s . 9 . 0
Freelength(mm)
Springrate(kg/mm)
278
315
3.2
2.0
2. Rearshockabsorber,435228700
( 1 ) T h e d a m p e n i n gc h a r a c t e r i s '
tics have been selected for
r a c i n gp u r p o s e s .
(2) Comparedto the stock unit,it
haslesstravel.
(3) lt is adjustableto allow chas'
s i st u n i n g .
5. Watt linkassemblY,
fateral arms: 435228 200
435228 400
center link: 435228 450
The connections are sPherical
rod ends instead of rubber bush'
ings. To allow changingthe roll
center. the center link has two
m o u n t i n gp o s i t i o n s .
Competition
6. Bumpstoprubber,435228320
To retain susPensiontravel de'
s p i t et h e l o w e r e dr i d eh e i g h tt,h i s
bump rubberis shorterthan the
stockversion.
ll. Machining and Installation Oper'
ations.
A. Steeringlinkage.
1. Reinforcemeo
n ft s i d e f r a m er a i l
(gear-box
attachmentPoint).
Fabricatea steel Plateand weld
to the side frame rail as shown
i n t h e i l l u s t r a t i o nT. h i s w i l l i n '
creasethe rigidityof the steering
linkage.
Gl'ir\$sltr/u r sg,t utrr-r rrrrlJ uusPL,NiriuN
H o l e sf o r s t e a r i n g e a r
b o xi n s t a l l a t i o n
Welding
Points
2. Mounting
s t r u ta s s e m b l y .
W h e nm o u n t i n gt h e c o m p e t i t i o n
s t r u t a s s e m b l y t, h e p o s i t i o no f
t h e m a r k s h o u l db e t o w a r d st h e
o u t s i d er e a ra s s h o w ni n t h e i l l u s tration.
2. Steeringpostposition.
Fabricateand installa spacerbetweenthe dash paneland steering post mounting bracket as
3 . R e m o v aol f b u m p s t o p b r a c k e t s
o n t h e l o w e rc o n t r o al r m .
S i n c et h e k n u c k l ea r m c o n t a c t s
t h e b u m p s t o p b r a c k e t ,1 0 m m
m u s tb e c u t o f f t h e u p p e rs i d e ,a s
B. Frontsuspension.
1 . E n l a r g ei n s i d ed i a m e t eor f t h r u s t
bearing.
To acceptthe largerdiameterof
the competitionshock absorber,
t h e i n s i d ed i a m e t e o
r f the thrust
bearingmust be enlargedfrom20
t o 2 2 m ma s s h o w ni n t h e i l l u s t r a tion.
Thispart must be cut olf
4 . I n s t a l l a t i oonf a n t i - r o lbl a r .
T h ea n t i - r o lbl a rs h o u l db e m o u n t e d w i t h t h e h o l e sd o w n w a r da, s
shown.Thereare four positions,
but hole #2 is the standardsett i n g a n d s h o u l db e t h e s t a r t i n g
p o i n tf o r c h a s s i sa d j u s t m e nbt e foretryinganyof the others.
41
AND SUSPENSION
CHASSIS/STEERING
( 2 ) A x l eh o u s i n gm o u n t s .
The standardPositionis the
#2 hole; trY it first' The disjoints
tancebetweensPherical
m
m
.
i
s
4
9
5
l
i
n
k
ona lower
T e n s i o nr o d .
T h o u g ht h e r e a r e t w o m o u n t i n g
h o l e s t, r y t h e u P P eor n e f i r s ta s i t
is the standardsetting'
Rear susPenslon.
' 1 . L o w e rl i n k i n s t a l l a t i o n .
( 1 ) C h a s s i sP i c k ' u PP o i n t s Fabricate 5 mm thick reinforcements and weld them in
place as shown below.
2 . U p p e rl i n ki n s t a l l a t i o n ',
( 1 ) A x l eh o u s i n gm o u n t s .
ln this case,hole #1 is the
standardsetting and should v
be tried first. The distance
b e t w e e ns p h e r i c a jl o i n t s o n l.
t h eu P P elri n ki s 4 1 3m m .
r Q
z Q
sO
GHAtS$ttrlir
r r-sr rr ;ir r.
r g l"r rir;(ll
u;*r-rf
fJl{
3. Fabricateand weld the brackets
for theWatt linkas shownbelow.
Bracket(Right)
o f c e n t e rl i n k .
4. Mounting
Thereare two mountingPositions,
but #1 is the standardsettingand
shouldbe triedfirst.
--ll
/a
o
Ot
S c a l e :1 / 4
5 . M o u n t i n go f r e a ra n t i ' r o l lb a r '
The mounting location on the
c h a s s i s i s i d e n t i c a lt o t h e s t o c k
position. The correct center-tocenter distance for the rod end
c o n n e c t i n gl i n k i s 1 0 0m m .
AND SUSPENSION
CHASSIS/STEERING
6. Mountingof frontanti'rollbar.
As a resultof the largerdiameter
of the bar,the side framerails
must be relievedbY cutting as
s h o w ni n t h ei l l u s t r a t i o n .
T h i sp a r t m u s t
becut off
(3) AnYnoisesfrom the internals
o f t h e g e a r b o xi n d i c a t et h e
complete steering gearbox
s h o u l db e r e p l a c e d '
2 . C e n t e rl i n k , t i e i o d a n d k n u c k l e
arm.
W h e nr e P l a c i ntgh e s eP a r t se' x e r '
cise care not to damagethe rub'
b b rb u s h i n g s '
3 . M a x i m u ms t e e r i n ga n g l e '
T h e m a x i m u ms t e e r i n ga n g l e i s
1 % t u r no f f c e n t e ro f t h e s t e e r i n g
w h e e li n e a c hd i r e c t i o nl't s h o u l d
be adjustedbYthe stoPPeron the
k n u c k l ea r m .
7. Sideframemodification.
With the reinforcedcrossmember. the side frame rail flanges
must be cut as shown.After cut'
t i n g ,i t m u s tb e r e w e l d e d .
B. SusPension.
1 . R o de n da l i g n m e n t .
( 1 ) A l l r o de n d ss h o u l db e a d j u s t '
e d w i t ht h e c a ro n t h e g r o u n d ,
alignmentis shown
andProPer
below.
C o r r e c ti n s t a l l a l i o n
h
lll[ll-]
t-JJ
here
\-wetd
p a r tm u s tb ec u to ff
il1.Checks,Adiustmentsand Main'
tenance.
A. Steering.
1. Steeringgear'
(' 1 ) T h e l u b r i c a n tr e q u i r e m e ni ts
SAE90 wt and the caPacitYis
1 7 0c c .
(2) The free PlaY is 10-15mm
measured at the steering
wheelrim.
l n c o r r e c ti n s t a l l a t i o n
(2) Note the correct Positi.on.of
the spacers as shown in the
illustration.
(3) Check the rod ends for wear
or cracking on the threaded
portion.
c. FrontsusPension.
1. Alignment.
(' 1 ) T h e f r o n t e n d a l i g n m e n ct a n
be adjustedwith the rod end
joints.
Note: When checking any
c h a s s i s a l i g n m e n t ,t h e c a r
s h o u l db e f i l l e d w i t h 1 5 g a l '
lonsof f uel and havea Person
in the driver'sseatto simulate
t h er a c i n gw e i g h t .
(2) Camber.
with'
Thecamberis adjustable
i n a r a n g eo f - 1 ' 0 " t o - 3 ' 0 ' '
Oneturn of the lowerarm rod
end joint alters the camber
7'.
bYaPProximatelY
CHASSIS/STEERI
NG AND SUSPENSION
(3) Toe-in.
O n et u r no f t h et i e r o dw i l l
c h a n g et h e t o e - i nb y a p p r o x i m a t e l y5 m m .
2. Shockabsorber.
The shockabsorberhas an eightp o s i t i o na d j u s t m e n tt;h e h i g h e r
t h e n u m b e r ,t h e m o r e s t i f f n e s s
and control.The shock absorber
s h o u l db e a d j u s t e dt o s u i t i n d i v i dualpreferences.
(2) Checkingthe shock absorbers.
Setbothrightand left sidesto
the same position.Compare
s t i f f n e s sb, o t ho n b o u n c ea n d
rebound.Also,checkfor bent
pistonrods.
3. Frontanti-rollbar.
Thereare four holes in the ends
of the anti-rollbar to allow chass i s t u n i n gt o s u i t p r e f e r e n c eosr
coursecharacteristics.
Springrates(kg/mm)
No.1
No.2
No.3
No.4
2.92
2.79
2.65
2.53
Hole #2 is the standardsetting
and shouldbe used as the basel i n e f o r c h a s s i sa d j u s t m e nat n d
tuning.
4. Checkthe rod end jointsthrougho u t t h e f r o n ts u s p e n s i ofno r w e a r
o r c r a c k i n go n t h e t h r e a d e dp o r tions.
5. Lubrication.
Molybdenum
d i s u l f i d e( M o S z i)s
r e c o m m e n d efdo r c h a s s i sl u b r i joints.
cationon anyappropriate
D. Rearsuspension.
1. Shockabsorber.
(1)Attaching
t h ea d j u s t i n g
diat.
a) Turn the adjusting shaft
c o u n t e r c l o c k w i sa
el l t h e
wayto the endof its travel.
b ) O n t h e a d j u s t i n gd i a l ,t u r n
t h e p o i n t e tr o p o s i t i o nN o . 1 .
c ) S e t t h e a d j u s t i n gd i a l o n
t h e s h o c ka b s o r b ear n d r o t a t e i t , s t o p p i r r gw h e n i t
m a k e sa c l i c k - l i k es o u n d .
Thenlockthe adjustingdial
i n p l a c ew i t ht h el o c k n u t .
T h e s es t e p sa r e s h o w ni n t h e
illustration.
( 2 ) T h e r ea r e e i g h t a d j u s t m e n t s
on the shock absorbers.The
h i g h e rt h e n u m b e rt,h e f i r m e r
t h e s h o c k a b s o r b e rw i l l b e .
T h e s h o c k ss h o u l db e a d j u s t e d t o s u i t i n d i v i d u a lp r e f e r e n c e sa n d c h a r a c t e r i s t i cosf
t h ec o u r s e .
( 3 ) C h e c k i n gt h e s h o c k a b s o r b ers.
Setboth left and rightsidesto
t h e s a m e s e t t i n g ,t h e n c o m parestiffnesson both bounce
a n d r e b o u n dF. i n a l l y b
, e sure
thereareno bentpistonrods.
2 . U p p e lri n k .
T i g h t e nt h e u p p e r t i n k w i t h t h e
car on the groundfor properalignm e n ta n dl o a d i n g .
E. Break-inprocedure.
1 . N e wf r o n th u bb e a r i n g s h o u l db e
broken-infor at least 50 km (30
mi).
2 . A f t e r i n i t i a l b r e a k - i nc, h e c k t h e
p r e l o a do n t h e h u b b e a r i n gl.t i s
i m p o r t a ntth a t i t b e 0 . 6 - 1 . k2 g a t
t h ew h e e cl l i pb o l t .
3 . l f t h e e n t i r es u s p e n s i o h
na sb e e n
rebuiltwith newparts,the system
must be broken-infor a total of
200km (120mi)as follows:
100km (60 mi) at 30 percentfutl
l o a d t, h e n :
100km (60 mi) at B0 percentfutl
load.
Afterbreak-in,
retightenthe entire
s u s p e n s i osny s t e m .
45
AND SUSPENSION
CHASSIS/STEERING
Tightening Torques For SuspensionGomponents
" S t e e r i n a"
: ----
T o r q u e ,k g - m
-+-
G e a r b o xt o f r a m e r a i l
4.4-5.5
13.0-17.0
Pitmanarmto sectorshaft
3.0-4.0
S t e e r i n gw h e e l t o s h a f l
3.0-4.5
7.0-8.0
Tie rodsPhericalrodglls--Tie rod lock nuts
4.4-5.5
ldlerarmto {rameraili
susPension'
S h o c ka b s o r b e rt o k n u c k l ea r m
pistontodto lg'nt'ng ilo"k
Sno"t absorber
Lowerarmto crossmember
C r o s s m e m b e tro s i d e f r a m e r a i l
T e n S i o nr o d t o f r a m e m o u n t i n gp o i n t
Tensionrodto lowerarm
8.0-9.5
6.5-8.2
7.6-9.5
3.8-4.7
' ' R e a rs u s P e n s i o. -n
bolts,bothends
Upperlinkattachment
L o w e rl i n k a t t a c h m e n tb o l t s ,b o t h e n d s
W a t t l i n k a t t a c h m e n tb o l t s ,b o t h e n d s
limit'
N o t e : B o l t s s h o u l db e t i g h t e n e dt o t h e u p p e r
7.6-9.5
7.6-9.5
APPENDIX
COMPARISON
OF SPECIFICATIONS
RX-7and RX-3
( E n g i n ea n d D r i v e l i n e )
Eng i n e
Basic performancespecifications.
2 7 0 P S a t 9 0 0 0R P M
M a x i m u mt o r q u e
23 kg-m at 8000 RPM
Basic mechanicalspecifications.
Displacement
Layout
5 7 3x 2 ( 1 1 4 6 c c )
<-
two rotors
<-
ratio
Compression
lntakesystem
9.4:1
+-
port
peripheral
<-
Exhaust
system
p e r i p h e r a pl o r t
+-
Carburetion
downdraftWeber
<__
Lubrication
wet sump
Coolingsystem
watercirculation
l g n i t i o ns y s t e m
f u l l t r a n s i s t oC
r DI
<<_
p o i n td i s l r i b .
Major parts specifications.
Rotor housing.
T r o c h o i ds p e c .
_
Rxa = l92lt____
Rxa=101x
i m p r o v e m e n ft o r c o o l i n g
n t a k et i m i n g
Port shape
E x h a u st i m i n g
l . O . / 1 . C=. 8 6 " / 7 5 "
"D" Port
E . O . / E . C=. 7 3 " / 6 5 "
Port shape
EllipticalPort
S p a r kp l u g l o c a t i o n
a n d h o l ed i a m e t e r
T/L = 30/18
TIL = 4.2112
<-
R o u n dP o r t
.+-<-
Side housing.
acetreatment s p e c i a lc a s t i r o n / g a sn i t r o g e n
Material/surf
plugged
port
Intake
Ventilation
0 . 5l i t e ro i l s e p a r a t otra n k
s p e c i a lc a s t i r o n
r e c l u i r e sp l u g g i n g
r e q u i r e sm a k i n g
s e p a r a t o rt a n k
Oilpan.
C o n fi g u r a t i o n
l a r g ec a p a c i t yw i t h
b a ff l e p l a t e
b a ff l e p r e v e n l sl o s s
of oil pressure
2 p c s ( b o t hs i d e s o f
b a f f l ep l a t e )
4T
APPENDIX
Tenslon bolts.
RX-7
r u b b e rb o n d e dt o c e n t e r
to removeresonant
vibration
Front cover.
Stationary gear.
Treatment
nitrogen
hasgroovesto relievestress
groovesmustbe
machined
Main bearing.
stock
Oilclearance
50p-80p
Material/treatment
C o m b u s i o nc h a m b e r
s p e c i a lc a s t i r o n / c h r o m e plated apex seal groove
<_
501t.-701t
+-
M . D . R .( M e d i u mD e e pR e c e s s )
A p e x s e a l g r o o v ew i d t h
Sidesealgroove
I n t e r n a lg e a r
3mm
6mm
1
2
h e l d i n p l a c eb y s n a p r i n g
Rotor bearing.
stock
S e c u r i n gm e t h o d
Oilclearance
<_
c l i n c hl o c k a n d l o c k i n g
screw
c l i n c hl o c k
70p - 100tL
70p -90p.
two-piece
one-piece
Eccentric shaft.
Flywheel.
Balanceand counterweight.
combination
with flywheel
o v e r s i z ei s a v a i l a b l e
APPENDIX
Apex seal.
Material/thickness
C o n fi g u r a t i o n
RX-7
TMC-15T/3
mm
o n e - p i e c ew i t h o u t t a p e rc u t
RX.3
TMC-15T
TR230/6mm
o n e - p i e c ew i t h
t a p e rc u t
I
Apexsealspring.
Corner seal.
Groovefor apexseal
Treatment
Configuration
3mm
Molybdenum
sprayedsurface
+-
solid
+-
6mm
Side seal.
Material
one-piece
molybdenum
sprayedsurface
two-piece
stock
S i d es e a l s p r i n g .
Oilseal.
s t o c k ( ' 7 9m o d e l )
Oil seal spring.
in. 15kg (stock)
o u t . 1 3k g
i n . 1 5k g ( s t o c k )
out.8 kg (stock)
Seal clearance.,
AG
0.06-0.07
0.05-0.06
AS
0.09-0.11
0.020-0.048
0.09-0.12
AC
AE
0.05-0.15
AH
0.15-0.20
0.13-0.17
0.4-0.7
AR
AF
<_
0.10-0.15
+<-
Intake manifold.
Totallength
M a n i f o l dl e n g t h
Mounting
angle
420
400
front155,rear165(mm) front135,rear145(mm)
4" 40'
5'05'
49
APPENDIX
Lubrication sYstem. -/
regulator
Pressure
_ _Q!7 -7.0kg/cm'
S a fe t y v a l v e
11 . 0k g / c m '
OilpumP.
RX.3
6.5 kg/cm'
l
. -.)
-.hrJt**"t tt;"t.
rotor:gasnitrogen -
I
i
i
+
-
1-
I
I
I
_l
Water PumP.
lgnition system.
Type
_l
-l
f u l l t r a n s i s t o r( C D l )
20' BTDC[r/L)
none
_)
-t
Spark Plu9.
E P Dt y p e0 . 5m m
-JI
I
j
High tension wires.
carboncore
-_--t
l_-__-
Alternator.
CapacitY
Starter.
-[-
directtYPe
*otu capacitY
__rgr9!ry!9--I
a b o v er e a r h o u s i n
;:g
l _
Drive pulleY.
castiron
Material
P u l l e yd i a m e t e r
Fuel pumP.
e l e c t r o n i c t, w o r e q u i r e d
2 . 0l i t e r s P e rm i n
Operation
Pressure
0.3kg/cm'
lorRx-7
I
APr-E.IYU'A
Exhaust system.
RX-7
-
RX-3
,--
S U S 3 0 44, 2 m m d i a
x 1 . 5m m t h i c k
d u a l p i p e s :2 3 0c m
c o l l e c t o r 1: 0 0c m
,<F-
-_-l
Remarks
I
i
l
j
;
;;r;."
s p l i tt y p e( F& R )
s l i d i n gc o n n e c t i o n
i
i ';6;;r",;";;;;-1
i
l
boGolL"^g"l-
s l i d i n gc o n n e c t o r
conneclor
lo.Jri"oiliiv I
I
I
-.t
Oilcooler.
500x164x49
r _ j
'--lll
560x400x49
-a
li-
airlaluminurn
I
Badiator.
air/aluminum
Spec.
A
D
B
--:
E
243.0
F
G
40.0
2111
983 ((575)
1 pc.
303.0
40.0
224e
968(,r65)
1 pc.
243.O
40.0
2't17
RX-7Comp.
806.0
546.0
11 2 . 0
968 (,i'57)
2 pcs. (065)
RX-3Comp.
860.0
550.0
205.0
RX-7Stock
806.0
546.0
1't0.0
A l l d i m e n s i o n sa r e g i v e ni n m i l l i m e t e r s .
51
APPENDIX
Transmission
R X - 3C o m p .
RX-7Comp.
H735mm
e68'5mm
A.A'
A-A'
W e i g h t :a p p r o x .4 0 k g
W e i g h t : a p p r o x 3. 6 k g
Differential
A: RX-7243.0mm
(comp.andstock)
RX-3303.0mm
(comp.andearlYmodelstock)
areheavyduty
carrierandrearbearingfor RX-7competition
Differential
whileRX-3usesstockParts.
,i
rr
ii; ;

RX7 Competition Manual

Transcription

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