iupui motorsports engineering mazda miata manual

1991 Mazda MX-5 MiataSCCA F Production Documentation Manual

TECH DATA & GENERAL SPECIFICATIONS GIWeights LF RF LR RR TotalTanks Empty W/o Driver W/o 483 490 389 409

Contents Section

Tech Data/General Specs GI

Service & Maintenance A

Engine B

Electrical System C

Power Transmission & Diff D

Braking System E

Suspension F

Steering G

Wheels H

Body I

Interior J

Contingency Awards K

SCCA Data & Regulations L

Misc. M

BallastTanks Full W/ Driver W/o Ballast 483 520 412 422Tanks Full W/o Driver W/o Ballast 565 518 468 470Tanks Full W/ Driver W/ Ballast 1 566 532 480 495Tanks Full W/ Driver W/ Ballast 2 560 547 494 510Tanks Full W/ Driver W/ Ballast 3 578 549 500 517Tanks Full W/ Driver W/ Ballast 4 572 549 522 540Tanks Full W/ Driver W/ Ballast 5 573 552 522 543Tanks Full W/ Driver W/ Ballast 6 563 559 535 551

Cross Note

52lbs behind fuel cell38lbs behind fuel cell32lbs driver foot well

39lbs trunk front

8.5lbs pass footwell18lbs trunk right side

Dimensions Capacities UnitWheelbase 89.2 inches Fuel GallonsFront Track 59.4 inches Engine Oil QuartsRear Track 59.9 inches Accusump QuartsOverall Width 70.25 inches Oil Change w/ Filter QuartsFront Wheel Hub to Wheel Hub 60.25 inches Gearbox QuartsRear Wheel Hub to Wheel Hub 60.75 inches Differential Quarts

Brake Master Cylinders Fluid OuncesClutch Master Cylinders Fluid Ounces

Miscellaneous Weight

Driver185 lbs Exhaust

Long Block Assembly w/ stand217 lbs Prmary Diameter

Transmission alone w/ shifter 76 lbs Primary LengtthSecondary DiameterSecondary LengthTotal Exhaust Length

Any additions to this manual shall proceed its sections previous documents and be formatted accordingly.

EngineCam Max Intake Lift 0.39 inches IntakeCam Max Exh Lift 0.389 inches System DiameterCam intake Duration @ .050" 223 degrees System Centerline LengthCam Exh Duration @ .050" 192 degrees LayoutCompression RatioRadiator Size Lubricants & Fluids

Oil Cooler SizeEngine Oil w/ cooler and lines

Transmission75W90 Full Syn

Differential75W90 Full Syn

Transmission & Differential Coolant1st gear ratio 2.02:1 Brake Fluid2nd gear ratio 1.54:1 Wheel Bearing Grease3rd gear ratio 1.21:14th gear ratio 1.1:15th gear ratio .87:1Reverse gear ratioDiff ratio 4.86:1

TECH DATA & GENERAL SPECIFICATIONS GI


TECH DATA & GENERAL SPECIFICATIONS GI

SERVICE & MAINTENANCE A

TOOLING REQUIREMENTS --------------------------------------------------------------------A-1

JACKING INSTRUCTIONS -----------------------------------------------------------------------A-2

START UP/SHUT DOWN SEQUENCE --------------------------------------------------------A-3

A-1


Tooling Requirements

1. 24mm Socket or Wrench to drain Transmission and Differential2. 23mm Socket or wrench to fill Differential

A-2

Jacking Instructions

1. Start with either the left or the right side of the car.2. Under the front fender, look for two notches underneath the rocker sill on

the pinch weld at each corner (Figure 1). These notches mark the jacking point of the vehicle. 2a. do not use the box tubing underneath.

3. Using the low-profile jack, raise the vehicle slowly. 4. With the vehicle at the desired height, place a black/grey NAPA jack stand

(Figure 2) at both the front and the rear of the frame rail. Be careful as to place the jack stands where the frame rails have a solid reinforced section (Figure 3).

5. Center the jack stands so the frame rail fits snug within the saddle of the jack stand

6. Lower the jack and repeat steps 1-5 on the other side. 7. Once all four jack stands are in place, lower the vehicle until it sets on all

four jack stands.8. Without moving the jack, raise it until it makes contact with the side sill of

the vehicle.9. Once the jack makes contact with the vehicle, give half a pump to the jack

to ensure it sits tightly against the vehicle 10. Rock the vehicle side to side to ensure that it is resting flat on the jack

stands with no tilting in any direction. This ensure that the vehicle will not fall under any circumstances.

A-3

Start Up/Shut Down Sequence


Starting Sequence

1. Turn on the ignition switch2. Wait for fuel pressure to rise until it stabilizes3. Open Accu-Sump and wait for 40 psi oil pressure4. Just cracking the throttle open, push the starter button5. Car idles at 2,000 rpm

Shut Down Sequence

1. Raise rpms to reach 60 psi pressure and hold2. Close Accu-Sump3. Idle the engine4. Shut off the ignition switch to turn off engine

ENGINE B

EXHAUST SYSTEM MEASUREMENTS ------------------------------------------------------ B-1

HEADER MEASUREMENTS -------------------------------------------------------------------- B-2

EXHAUST DIAGRAM ---------------------------------------------------------------------------- B-3

STARTER REPLACMENT PROCEDURE ------------------------------------------------------ B-4

FUEL SYSTEM ------------------------------------------------------------------------------------- B-5

SYSTEM SPECIFICATIONS -------------------------------------------------------------- B-5Any additions to this manual shall proceed its sections previous documents and be formatted accordingly.

FUEL FLOW INDEX --------------------------------------------------------------------- B-6

B-1 EXHAUST SYSTEM MEASUREMENTS

This document contains the approximate lengths of each individual section of exhaust piping on the Mazda Miata.

Primary Lengths

These are the approximate primary (head-) pope lengths (1 being front, 4 being rear).

1. 26.75”2. 25.5”3. 23.75”4. 15.00”

Primary Collector Lengths

These are the approximate secondary collector length.

1. 7.5”2. 7”

Secondary Collector Length

This is the approximate secondary collector length.

1. 7.5”

Mid Pipe Length

This is the approximate mid-pipe length from the secondary collector to the muffler

1. 32.25”

Muffler Length

This is the full length of the muffler casing.

1. 10.50”


Tailpipe Length

This is the tailpipe length from the muffler to the exhaust exit.

1. 12.00”

B-2 Header Measurements

Header Exit Piping Diameters

Header Exit 1.6"

Primary Collectors 1.75"

Primary Exits 1.75"

Secondary Collectors 1.9"

Secondary Exit 2.25"

Single Exhaust 2.5"

B-3 Exhaust Diagram

B-4 Starter Replacement Procedure

Tools Needed

1. ½ inch open ended wrench2. 3/8 drive ratchet3. 14 mm socket4. 14 mm open ended wrench5. Jack and jack stands6. 3 inch extension7. 6 inch extension

Removal Procedure


1. Using the ½ inch open ended wrench, disconnect the positive cable of the battery

2. Jack up the car and place stands in appropriate positions. See instructions. 3. Disconnect the green wire with the spade connector from the starter

solenoid4. Using the 14 mm open ended wrench, remove the top nut on the solenoid.

Then remove the washer followed by power wire. 5. Use the 14 mm open ended wrench to hold the bottom Bolton the back

side of the starter6. Place the 3 inch extension the 3/8 drive ratchet followed by the 14 mm

socket. Loosen and remove the bottom nut.7. Finally, replace the 3 inch extension with the 6 inch. Then loosen the top

bolt on the backside of the starter. (There is no nut to worry about)

B-5 Fuel System

System Specs

Individual Component Details

Fuel Cell: ATL - P/N SU108 Dimensions: 20.5” x 12.5” x 9.13” Capacity: 8 gallons

Fuel Cell Fill Plate: ATL – P/N TF600 (with -6 AN outlets

Fuel Filter:

Fuel Pump:

Fuel Pressure Regulator: Trick Flow by Aeromotive - P/N TFS-27001

Fuel Rail: M-Tuned Rail for 90-93 1.6L Mazda Miata Volume: 4.6875 sq.in

Fuel Injectors:

Other Notes

B-6 Fuel Flow Index


ELECTRICAL SYSTEM C

OPTIMA BATTERY ------------------------------------------------------------------------------- C-1

CHARGER SETTINGS -------------------------------------------------------------------- C-1

CHARGING TIME ------------------------------------------------------------------------ C-1

CHARGER INSTRUCTIONS ------------------------------------------------------------- C-1

AMB TRANSPONDER MANUAL ------------------------------------------------------------- C-2

TABLE OF CONTENTS ------------------------------------------------------------------- C-3

C-1 Optima Battery

Specs

AGM Deep Cycle

Part No: N9934YEL

Model No: 34

Capacity: 55 AhCharger Settings

Charger Type Amps Target VoltsRegular/Automatic 10 13.8-15.0Float 1 13.2-13.8

Charging TimeCharger Setting

Capacity (aH) 2 amps 5 amps 10 amps


38 23 hours 9 hours 4.5 hours44-55 33 hours 13 hours 6.5 hours46-75 45 hours 18 hours 9 hours

Using the Charger

1. Plug Charger into wall. “Connected” light will glow.2. Select batter type “AGM”. -YOU MUST USE AGM. SELECTING ANOTHER TYPE CAN DAMAGE THE BATTERY.3. Select batter size “8A Medium” to being charging4. Let battery charge for 8.5 hours

C-2

AMB Transponder Manual

1

ContentsINTRODUCTION..........................................................INSTALLATION OF THE DETECTION LOOP.................2.1 Positioning.........................................................2.2 Installation of the detection loop.........................2.3 Testing the detection loop installation.................. INSTALLATION/OPERATION OF THE TRANSPONDER..3.1 Installation of the transponder.............................3.2 Charging instructions..........................................


INSTALLATION/OPERATION OF THE DECODER.........4.1 Installation of the decoder...................................4.2 Operating the decoder........................................AppendicesAPPENDIX A - FREQUENTLY ASKED QUESTIONS..............APPENDIX B - USEFUL TOOLS/PARTS/EQUIPMENT............APPENDIX C - TECHNICAL SPECIFICATIONS......................APPENDIX D - CE AND FCC REGULATIONS.........................GUARANTEES & WARRANTIES..........................................FiguresFigure 1.1 System overview...............................................Figure 2.1 Detection loop installation overview....................Figure 2.2 Soldering the loop wire end...............................Figure 3.1 Transponder placement.....................................Figure 3.2 Fastening the Direct Powered transponder..........Figure 3.3 Fastening the transponder in the holder..............Figure 3.4 Charging cradle................................................Figure 4.1 Connecting the TranX decoder............................


a) The detection loop must be positioned in such a way that the transponder is above the center of the detection loop when the front of the cars/motorcycle crosses the finish line. Make sure cars/motorcycle cannot pass outside the detection loop. Extend the detection loop outside the track if necessary.

b) One loop can be used for a track width of max. 10m (33ft). For wider tracks use 2 or 3 (max.) loops. When 2 or 3 detection loops need to be installed, make them of even length with 10 cm (4”) overlap.

c) With a seperate loop in the pitlane, connected to the BNC connector marked, loop 3 (PIT) on the decoder, passings registered in the pit lane can be identified as such by the decoder.

d) The detection loop is sensitive to interference, sometimes emitted by nearby cables. When possible, keep other cables 5 m (15 ft) away. Also, make sure cars/motorcycles or other parts on the track will not get closer than 5 m (15 ft) to the detection loop, to avoid false inputs.

e) For dirt tracks, the detection loop is best installed in plastic conduits at a maximum of 30cm (1ft) below the surface. The maximum depth should be chosen in a way that the cars/motorcycles cannot dig out the detection loop. However please respect the maximum distance between loop and transponder, which is 60cm (2ft) for cars and 120cm (4ft) for motorcycles.

LEARNED BY EXPERIENCEWhen pulling the detection loop wire through the plastic conduit, it is a good idea to pull another non-metal wire through. This wire then can be used to install a new loop wire in case it gets damaged.

2.2 Installation of the detection loop a) Cut the slots in the track a maximum of 2 cm (3/4 in) deep and 60 cm (2 ft) apart. Make sure the slots are clean and dry. This will ensure a perfect seal when the silicon is applied after the installation of the wiring. Any additions to this manual shall proceed its sections previous documents and be formatted accordingly.

Put the wires of the detection loop in the slots and cut the excess length of the detection loop wires.b) Widen the slot with a chisel where the small connection box of the loop is to be installed. Place the connection box vertically.c) When all wires are installed, put the heat shrinkage sleeve over a detection loop wire end. Then solder the loop wire to the short wire end of the connection box. When soldering the wires together, the solder should flow through the entire connection and not only around it. Now put the shrinkage sleeve over the soldered connection and hold it over a heatsource to shrink the sleeve (also see the drawing below). Repeat this procedure for the second wire of the detection loop.

d) Fill the slot with silicone. Before doing this, please test the loop as described in section 2.3. Make sure not to overfill the slots and that the silicone is fully under the surface of the track, otherwise tires may pull out the silicone.

If any silicone spills out of the slot, remove the excess silicone by scraping the top with a small piece of cardboard. This also ensures that the silicone is pressed into the slot for a perfect seal.

LEARNED BY EXPERIENCEIf you wish, you may pad the slots with backing rod or nylon cord before sealing the slot with silicone. This helps to prevent the excessive use of silicone and is also useful when pulling out the silicone if the detection loop has to be replaced.SiliconeAny additions to this manual shall proceed its sections previous documents and be formatted accordingly.

There is a wide variety of silicone types available in hardware stores; it is important that the right type is used. Silicone that can withstand different temperatures as well as both wet and dry conditions (since weather situations can vary ), should be used. If you are unsure, check the specifications of the silicone. The following types of silicone have been shown to yield lasting results and are recommended by AMB:•Dow Corning 890SL is a self-leveling silicone kit. It is applied as a liquid and fills the slot completely. •Purflex is a polyurethane-based silicone that retainsits elasticity under a wide range of temperatures.

2.3 Testing the detection loop installationOnce the loop has been installed, it should be tested to ensure that it is functioning correctly. We also recommend repeating the same procedure at the start of each race event. You can determine if your loop is functioning correctly by doing the following tests:a)Connect the detection loop to the decoder and computer running AMB i.t. timing software (also see section 4.1 Installation of the TranX decoder). Check the background noise, which is updated every five seconds in the AMB i.t. timing software. The background noise level should be between 0 and 40 points. A higher value may indicate interference by other electrical equipment in the area or a bad loop installation. Try switching off any suspected equipment or removing nearby objects and check for improvements. Especially at night, short-wave radio transmitters may cause an increased background noise (for more information see Appendix A).b)If a detection loop has been correctly installed, a transponder should be picked up at the same distance along the entire detection loop. To test this, stand at one end of the detection loop about 8 m (25 ft) away and hold a transponder approximately 120 cm (4 ft) off the ground. Walk slowly towards the detection loop. You will hear a beep in the headphones attached to the decoder when the transponder is detected. Mark the spot where the transponder was detected. Repeat the process for the middle and other


end of the detection loop and do the same coming from the other direction. The detection distance from the loop should be approximately the same for all positions (< 20% variation).c)Check the signal strengths of the transponders as they are picked up by the system during a reality test (also see paragraph 2.3 Installation of the Transponder). A good loop will yield consistent transponder signal strengths of at least 100 points with a hit rate of at least 10 points. The hit rate may vary depending on the speed of the transponder passings (slower passings yield higher hit counts), but the signal strength should be consistent (< 10 points variation).


Sleep modeA charged/functioning transponder can be put into a sleep mode by placing it in an unplugged charging cradle or charger case. Normal functioning resumes when it is removed from the cradle. While in Sleep mode, the transponder will last up to 3 times longer during a single charge-discharge cycle. The sleep mode is designed to turn off the transponder’s signal output and save battery life. It is necessary to use the Sleep mode when travelling by airplane to adhere to airline regulations.


AdviceCharge the transponder once every 3 months. Do not charge longer than necessary as this will reduce the life time of the battery. Doing so voids your warranty

d)Any additions to this manual shall proceed its sections previous documents and be formatted accordingly.

POWER TRANSMISSION & DIFFERENTIAL D

POWERTRAIN TECHNOLOGY APPLICATION GUIDE ------------------------------------ D-1

TABLE OF CONTENTS --------------------------------------------------------------------------- D-2

REAR AXLE INDEX ------------------------------------------------------------------------------- D-3

DIFFERENTIAL ------------------------------------------------------------------------------------ D-4

GEAR OIL CHANGE ---------------------------------------------------------------------- D-4

DIFFERENTIAL INFORMATION ------------------------------------------------------- D-4

D-1 Powertrain Technology Application Guide


BRAKING SYSTEM E

BRAKE SYSTEM OVERVIEW ------------------------------------------------------------------- E-1

STOCK ASSEMBLIES ----------------------------------------------------------------------------- E-2

BILL OF MATERIALS ----------------------------------------------------------------------------- E-3

HELLA VACUUM PUMP OVERVIEW -------------------------------------------------------- E-4

TECHNICAL DATA ------------------------------------------------------------------------ E-5

E-3 Bill of Materials

LFItem Type Part # Brand Cost Qty VendorCaliper SE1929A CAL 52.49 1 NAPARotor 941334 Brembo 40 1 NAPABleeder Screw 25214 UP 3.49 1 NAPACaliper seal kit 1525 UP 4.99 1 NAPACaliper Pins 82683 UP 6.99 1 NAPA

Corner Total 107.96

LRItem Type Part # Brand Cost Qty VendorCaliper SE1929A CAL 87.49 1 NAPARotor 941346 Brrembo 38.99 1 NAPABleeder Screw 675-1572 NOE 16.99 1 NAPACaliper Pins 83000 UP 7.49 1 NAPA

Corner Total 150.96

RF

Item Type Part # Brand Cost QtyVendor

Caliper SE1929A CAL 52.49 1 NAPA

Rotor 941334 Brembo 40 1 NAPA

Bleeder Screw 25214 UP 3.49 1 NAPACaliper seal kit 1525 UP 4.99 1 NAPA


Caliper Pins 82683 UP 6.99 1 NAPA

Corner Total107.9

6

RR

Item Type Part # Brand Cost QtyVendor

Caliper SE1929A CAL 87.49 1 NAPA

Rotor 941346 Brembo 38.99 1 NAPA

Bleeder Screw675-1572 NOE 16.99 1 NAPA

Caliper Pins 83000 UP 7.49 1 NAPA

Corner Total150.9

6

E-4 HELLA VACCUME PUMP


SUSPENSION F

TOE PLATES --------------------------------------------------------------------------------------- F-1

CONDITIONAL STATEMENTS --------------------------------------------------------- F-1

SETTING TOE ----------------------------------------------------------------------------- F-1

RIM CLAMP --------------------------------------------------------------------------------------- F-2

WHEEL ALIGNMENT PROCEDURES ------------------------------------------------- F-2

WHEEL RUNOUT ------------------------------------------------------------------------- F-2

JRI SHOCKS P.O. --------------------------------------------------------------------------------- F-3

FORCE VS. VELOCITY GRAPH --------------------------------------------------------- F-4

ADJUSTER OPERATION ------------------------------------------------------------------------ F-5

DAMPERS ----------------------------------------------------------------------------------------- F-6

SWAY BAR DATA -------------------------------------------------------------------------------- F-7

FRONT & REAR SPRING RATES -------------------------------------------------------------- F-8

MISC SUSP CALCULATIONS --------------------------------------------------------------- F-9-10


STEERING SYSTEM G


WHEELS H


BODY I


INTERIOR J

RACING HARNESS ------------------------------------------------------------------------------- J-1

DESCRIPTION ----------------------------------------------------------------------------- J-2

RACING SEAT ------------------------------------------------------------------------------------- J-3

FIRE EXTINGUISHER ---------------------------------------------------------------------------- J-4

J-1 Racing Harness

Information

Brand Racequip

Item Weight 6.7 lb

Manufacture Part Number 754004

Date First avaliable 1-Jan-12

J-2 Description

754004 FIA / SFI Pull up Lap – HANS Shoulder Camlock Harness

Exceeds Stringent FIA 8853/98 Standard Surpasses SFI 16.1 Rating 6 point design – dial 2” crotch strap Cam Buckle style affixed to the right lap belt Can be re-webbed (SFI Cert.) Upon Expiration Shoulder belt adjustment length is 20” to 70” Lab belt is adjustable from 25” to 70


J-3 Racing Seat

Sparco pro2000Part Number 00857FName Pro 2000 FMaterial FiberglassHomol FIA CS.917.98HANS NoneWeight 19 lb

Seal life: The usable life of an FIA homologated seat will be 5 years from the date of manufacture indicated on the seat label

An extension of up to further years may be authorized where the seat has been returned to the manufacture for re-validation. Extensions will be indicated by an additional label affixed to the seat identifying the date of the seat eligibility and validated by the manufacture quality inspection stamp.

CONTINGENCY AWARDS K

SYNOPSIS ----------------------------------------------------------------------------------------- K-1

SAFERACER --------------------------------------------------------------------------------------- K-2

SUMMIT RACING EQUIPMENT -------------------------------------------------------------- K-3

HOOSIER RACING TIRE ------------------------------------------------------------------------ K-4

MAZDA N. AMERICAN OPERATIONS ------------------------------------------------------ K-5

MAZDA & MAZDASPEED DECAL APPLICATION ----------------------------------------- K-6Any additions to this manual shall proceed its sections previous documents and be formatted accordingly.

SCCA DATA & REGULATIONS L

2015 SCCA RUNOFFS (DAYTONA) ----------------------------------------------------------- L-1

DRIVER LAP TIMES -------------------------------------------------------------------- L-1-2

RACE RESULTS ---------------------------------------------------------------------------- L-3

CHART -------------------------------------------------------------------------------------- L-4


MISC. M


iupui motorsports engineering mazda miata manual

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