USER MANUAL - Rev
USER MANUAL - Rev.02Page - 1 / 42SuperCar Lites User Manual Rev.02
1234567VIEWS OF SUPER CAR LITES . 3DIMENSIONS . 4BODY COLOUR - OE . 4CLEANING. 4CAPACITIES (from DRY) . 5TECHNICAL SPECIFICATIONS . 5SETUP . 67.1SETUP ADJUSTMENT . 77.2BELLCRANK SETTINGS . 87.2.1FRONT BELLCRANK SETTINGS . 87.2.2REAR BELLCRANK SETTINGS . 97.3ANTI-ROLL BAR STIFFNESS SETTINGS . 107.3.1FRONT ANTI-ROLL BAR STIFFNESS SETTINGS . 107.3.2REAR ANTI-ROLL BAR STIFFNESS SETTINGS . 117.4SUSPENSION SETTINGS . 127.4.1DEFAULT SUSPENSION SETTINGS . 138DASHBOARD . 148.1DASHBOARD INDICATOR AREAS . 148.2DASHBOARD SENSOR OUTPUT SCREENS . 159EPAS . 169.1CALIBRATION OF COLUMN . 1610ENGINE . 1710.1ENGINE OPERATING INSTRUCTIONS . 1710.2OIL SPECIFICATION. 1810.3ENGINE OPERATING BOUNDARIES . 1811POWER TRAIN . 2111.1GEARBOX . 2111.1.1GENERAL DETAILS. 2111.1.2RATIO CHARTS . 2111.1.3DIFFERENTIAL . 2111.1.4LUBRICATION . 2211.1.5MAINTENTANCE . 2211.1.6DRAWINGS . 2211.2FRONT DIFFERENTIAL. 3211.2.1GENERAL DETAILS. 3211.2.2RATIO CHART . 3211.2.3DIFFERENTIAL . 3211.2.4LUBRICATION . 3311.2.5MAINTENANCE . 3311.2.6DRAWINGS . 3311.3REAR DISCONNECT CLUTCH . 3711.3.1GENERAL DETAILS. 3711.3.2TECHNICAL DETAILS . 3711.3.3LUBRICATION . 3711.3.4DRAWINGS . 3712BRAKES . 4112.1PRE-BEDDING AT ALCON . 4112.2USE OF PRE BEDDED DISCS IN COMPETITION . 4112.3“RUNNING – IN” INSTRUCTIONS . 4212.4WEAR ALLOWANCE AND MAINTENANCE . 4212.4.1BRAKE DISCS . 4212.4.2BRAKE PADS . 42Page - 2 / 42SuperCar Lites User Manual Rev.02
1 VIEWS OF SUPER CAR LITES(Shipping Information Only)Page - 3 / 42SuperCar Lites User Manual Rev.02
2 DIMENSIONSOverall LengthOverall WidthFront Axle CenterlineRear Axle CenterlineWheelbaseFront OverhangRear mmm 1% 1% 1% 1% 1% 1% 1%3 BODY COLOUR - OE Chassis, Bonnet Front, Body Main, Body Rear, Spoiler: VWLB9A Wishbones, Pushrods, Bellcranks: Galvanized Coating, ColorSilver Gray Rear Progressive Pushrod: Cr3 Coating, Color Yellow4 CLEANINGCare should be taken when using pressurized water to clean thecar, especially around electronic sensors and wiring.Coils should be removed following washing and any water blownout of spark plug holes using compressed air.The car should be started and run back to operatingtemperature after washing to help dry components out beforestoring for any length of time.Page - 4 / 42SuperCar Lites User Manual Rev.02
5 CAPACITIES (from DRY)ProductsFuel (Championshipdepending)Fuel – GRC LitesEngine OilGearbox OilCoolantBrake FluidClutch FluidRear DisconnectClutch OilFront Differential OilQuantity20 liter0.55 literSpecificationsP1 Racing 102RXor Aspen R102Sunoco260 GT Plus10W6075W140Distilled Waterand anti–freeze(80/20 mix)DOT4 Brake FluidDOT4 Brake Fluid75W1400.7 liter75W14020 liter6.7 liter4 liter6 TECHNICAL SPECIFICATIONSWeightFront SuspensionRear SuspensionWheelsTiresBrakesEnginePowerTorqueRev CutOil Type1100 kg (non-homologated weight)Push-RodIndependent Double WishboneOHLINS TTX AdjustablePush-RodIndependent Double WishboneOHLINS TTX AdjustableRims: KMC17"X8" PCD4X108 ET60Cooper 215/40R17ALCON 330mm ventilated brakediscs with 4 piston brake calipers.2.400 cc - SuperCar Lites310 BHP @7800rpm300 Nm @5500rpm@8000rpm10W60Page - 5 / 42SuperCar Lites User Manual Rev.02
7 h10/3813/3613/2815/2719/2918/24Differential Front RearRampsAcceleration 37,5 45 Braking90 90 FrontSpring Stiffness (N/mm)Spring Free Length (mm)Helper Stiffness (N/mm)Helper Stroke (mm)DampersDefault ClicksLow Speed CompressionHigh Speed CompressionReboundAnti-Roll Bar StiffnessDefault SetupDefault Bellcrank PositionCaster [ ]Camber [ ]ToeAnti-DiveAnti-SquatWheel TravelCamber GainCircumference653001565OHLINS TTXAdjustableRear703001565OHLINS iumNon-Progressive Center HoleGeometry7 ----1 -1 0 0 %42,5%43,7%23240 mm-0,0146 /mm2042 mm2042 mmPage - 6 / 42SuperCar Lites User Manual Rev.02
7.1 SETUP ADJUSTMENT(For guidance only)AdjustmentFrontRearCamber Change1 turn of upper0,65 (Both0,7 wishbone turnbuckle turnbuckles)Caster Change (front)1 turn of front-0,85 turnbuckle(contraction)1 turn of rear-0,85 turnbuckle(extension)Toe Change1 turn of Rodend0,77 0,57 Page - 7 / 42SuperCar Lites User Manual Rev.02
7.2 BELLCRANK SETTINGS7.2.1FRONT BELLCRANK SETTINGSThere are two operations modes for the front suspension: Suspension Mounted to Point A: Non-Progressive Motion Suspension Mounted to Point B: Progressive MotionBoth modes have three individual stiffness options providingdifferent motion ratios, accompanied with different wheel travelvalues. Predifined front bellcrank positions and their effects onsuspension motion ratios are:Motion ive essive MotionB42400,520,83B52100,581,00B61800,661,25Page - 8 / 42SuperCar Lites User Manual Rev.02
7.2.2REAR BELLCRANK SETTINGSThere are two operations modes for the rear suspension: A) Pushrod Length l 300mm: Non-Progressive MotionPushrod color: Silver Gray, code AV4015 B) Pushrod Length l 330mm: Progressive MotionPushrod color: Yellow, code AV4145Both modes have three individual stiffness options providingdifferent motion ratios, accompanied with different wheel travelvalues. Predefined rear bellcrank positions and their effects onsuspension motion ratios are:Motion avelReboundCompressionPoint(mm)Non-Progressive MotionA - 300mm12400,580,71A - 300mm22100,660,83A - 300mm31800,830,90Progressive MotionB - 330mm42400,500,77B - 330mm52100,580,90B - 330mm61800,661,11Page - 9 / 42SuperCar Lites User Manual Rev.02
7.3 ANTI-ROLL BAR STIFFNESS SETTINGS7.3.1FRONT ANTI-ROLL BAR STIFFNESSSETTINGSThere are 3 different stiffness settings for front Anti-Roll Bar: Soft:Both (Left&Right) Anti-Roll Bar push rods on Position A. Stiff:Both (Left&Right) Anti-Roll Bar push rods on Position B. None:Removal of one Anti-Rollbar drop link.Page - 10 / 42SuperCar Lites User Manual Rev.02
7.3.2REAR ANTI-ROLL BAR STIFFNESS SETTINGSThere are 3 different stiffness settings for rear Anti-Roll Bar: Soft:Both (Left&Right) Anti-Roll Bar push rods on Position A. Intermediate:Both (Left&Right) Anti-Roll Bar push rods on Pos. B. Stiff:Both (Left&Right) Anti-Roll Bar push rods on Position C.Page - 11 / 42SuperCar Lites User Manual Rev.02
7.4 SUSPENSION SETTINGSRebound Set-Up Use a 3 mm allen key or tool. Turn the adjuster clockwise to fully closed position (positionzero [0]). Turn counter clockwise to set the adjuster to recommendednumber of clicks. If you want to change setting, adjust in steps of 2-3 clicksat a time. Focus on the main adjuster. Main adjuster has 5-40 clicksrange.,Compression Set-Up Low speed compression is adjusted by using a 3mm allenkey. High speed compression is adjusted with a 12 mm wrench.Page - 12 / 42SuperCar Lites User Manual Rev.02
We recommend you to adjust low speed compression in steps of2-3 clicks and high speed 3-5 clicks to fine tune the set up. Thelow speed adjuster has approximately 40 clicks and high speed50 clicks.To reset compression Turn the adjuster clockwise to fully closed position (positionzero [0]). Then, turn counter clock-wise to open, and countthe clicks until you reach the recommended number ofclicks. See recommended Set-up data in the MountingInstructions for each shock absorber/strut.CAUTIONDo not use force, delicate sealing surfaces can be damaged.Hand tighten only.7.4.1DEFAULT SUSPENSION SETTINGSFor Front and Rear Suspensions the default settings are asbelow:ReboundFrontRear2525High SpeedCompression2020Page - 13 / 42SuperCar Lites User Manual Rev.02Low SpeedCompression2020
8 DASHBOARD8.1 DASHBOARD INDICATOR AREAS RPM Indicator: Corresponding LEDs light up at indicatedengine rpm. Oil Pressure: Displays the current oil pressure. Oil Pressure Alarm: 3 LEDs light up if pressure is below 1,5bar. Battery Voltage: Displays the current battery voltage. Menu Selection: Switches between sensor displays. Engine Coolant Temperature: Displays the current coolanttemperature. Engine Coolant Temperature Alarm: 3 LEDs light up iftemperature is above 100 C. EPAS Power Level Adjuster: Adjusts the power level ofEPAS. CW softer, CCW stifferPage - 14 / 42SuperCar Lites User Manual Rev.02
8.2 DASHBOARD SENSOR OUTPUT SCREENSScreens can be switched by using menu selection buttons. Throttle Position: Displays the current throttle position over100. Lambda Sensor Output: Displays the current lambda sensorreading. Oil Temperature: Displays the current oil temperature. Fuel Pressure: Displays the current fuel pressure.Page - 15 / 42SuperCar Lites User Manual Rev.02
9 EPASThe vehicle is equipped with an Electrical Power Assist System.The user can adjust the level of assistance with the EPAS PowerLevel Adjuster next to the Dashboard pictured below: CW softer,CCW stiffer9.1 CALIBRATION OF COLUMNIt is normal for the steering wheel to move on initial power upand during calibration. Do not attempt to hold the wheel atthis time or the settings may become corrupted. Set Power Level Adjuster fully counter clockwise. Switch on “Electronics 12v” until LED (next to the PowerLevel Adjuster) lights up. Immediately switch off and thenback on until LED lights again. Continue to do this 3 more times until on the 4th time theLED lights and flashes, this is the calibration phase. The LED will extinguish at the end of calibration when youcan now use the system.Calibration only needs to be carried out once at installation asthe settings will be retained even when power is removed.If any unexpected behavior is observed with the EPAS, theowner shall contact the car manufacturer.Page - 16 / 42SuperCar Lites User Manual Rev.02
10 ENGINE10.1ENGINE OPERATING INSTRUCTIONSThe following should be carried out immediately prior tooperating the engine: The engine should be operated with Sunoco 260GT Plusfuel. Agreement to use another other fuel should be madewith Mountune prior to engine operation. Water level should be checked in the header tank and setto the mid position on the sight gauge. Additives such aswater wetter can be used, or antifreeze whereallowed(80/20 mix). With the ignition and fuel pumps on, the static fuelpressure should be set to 4bar by adjusting the fuelpressure regulator. The engine should be cranked on the starter motor, withthe ignition turned off to achieve oil pressure, (with thespark plugs removed to reduce the load on the big endbearings, if the engine is being started for the first time orafter standing for a long period). The cranking durationshould be limited to 5 second duration. If oil pressure is notachieved after 3 cranking events, please contact Mountunebefore taking any other action. If oil pressure is successfully achieved, switch ignition onand start the engine. Allow the engine to run until watertemperature reaches 85C. Check during this warm uprunning that the engine and its installation are free fromleaks. Oil level should be checked following this warm up run.Complete installation lap (where possible). Check watertemperature on track is within specified guidelines, andadjust radiator blanks as required to achieve this.If an engine failure occurs please contact Mountune Racingbefore taking any action, so as to avoid the loss of any evidencewhich may help understand the failure.Page - 17 / 42SuperCar Lites User Manual Rev.02
10.2OIL SPECIFICATIONA fully synthetic oil of viscosity range 10W60 should be usedsuch as Castrol, Shell Racing, Royal Purple or Mobil 1.10.3ENGINE OPERATING BOUNDARIESThe following operating limits for the engine should be observed.Engine speed Maximum – 8200 rpm Engine idle speed at operating temperature - 1800 rpm(TPS should be set to 4 – 4.5%) Engine speed 9000 rpm – Advise engine is removed.Water Temperature Maximum temperature – 100 C* Desired operating range – 75-85 C *Short excursions / heat soak (less than 90 seconds) abovethis temperature during start line procedures etc. will beacceptedOil temperature Maximum temperature – 130 C Desired operating range – 90 - 120 COil pressure Typical observed oil pressure at 110 C oil temp Minimum oil pressure at engine idle speed – 1.5bar @ 1800rpmPage - 18 / 42SuperCar Lites User Manual Rev.02
Fuel pressure Static pressure – 4bar*If the above operating conditions are exceeded MountuneRacing will decide either to remove the engine, or to continue touse the engine with a reduced life.Engine Management Safety StrategiesMountune Racing utilizes a number of safety strategies withinthe engine management system to assist in protecting theengine from operation outside of the operating conditions. Theseare as follows:Engine Speed Engine rev limit – set to 8200 rpm Engine rev cut – set to 8300 rpm Engine oil temp rev limit – below 65 C and above 130 C oiltemp a reduced rev limit is engaged – soft cut Engine coolant temp rev limit – below 65 C and above100 C water temp a reduced rev limit is engaged – soft cutPressure Protection Low oil pressure – as oil pressure decreases below protectvalue, an oil pressure cut trip timer is started. If oilpressure cut trip timer exceeds 1.5 seconds a completeengine cut is applied.Oil Level The oil level should be run just below the top baffle, orbetween 18-20cm from the bottom of the dry sump tank.Page - 19 / 42SuperCar Lites User Manual Rev.02
This should be checked before every run, it is the team’sresponsibility to do this.Data Analysis AEM/engine data should be checked after every run toensure maximum engine performance, this is the team’sresponsibility.Service IntervalsThe following service intervals should be observed: Engine – Mountune recommend engines should be servicedat the end of each season Oil and Filter - replace every 300km FEAD belt - replace on condition. Air filter – clean and inspect after every race, and replaceon condition, check airbox is sealing correctly Inlet – should be inspected and maintained after everyevent. Sent back to mountune for servicing at the end ofeach season. Alternator bracket o-ring bushes – replaced on condition,no longer than 3 events apart. Water radiator and pipe work – pressure test, replace oncondition Oil cooler and pipe work – pressure test, replace oncondition Catalyst – replace on conditionImportant:In the event of an engine failure - the complete oil systemshould be drained, flushed through and thoroughly cleaned. Inthis case the Laminova oil cooler should be replaced and NOT reused. When the new engine is installed the AIM dash should bereset to ZERO engine running hours.Page - 20 / 42SuperCar Lites User Manual Rev.02
11 POWER TRAIN11.1 GEARBOX11.1.1 GENERAL DETAILSThe Supercar Lites SL90-20 gearbox is composed of a 6 frontspeed reverse. Its weight is approximately 72 kg withoutcable of reverse gear.It is equipped with a self-locking differential with friction discsand pressing plates with ramps. The reverse gear unlockingcable, the lubrication pump and its suction screen, and thegearing potentiometer are also provided.11.1.2RATIO CHARTS1st10PrimaryShaftSecondary 38Shaft2nd133rd134th155th196th183628272924Bevel GearReverse Gear8x31Primary11Idler23Secondary4411.1.3 DIFFERENTIALZF type self-locking differential with triple friction discs andpressing plates with ramps acting symmetrically or not, fordriving or braking condition.driving ramp 45 braking ramp 90 Preload 60NmNote: A fell of preload from approximately 15% after 60kilometers running in will be note.Note: The cold measured preload (workshop) is approximately15% higher than that measured hot.Note: The Pre-load is measured at the differential flange.Page - 21 / 42SuperCar Lites User Manual Rev.02
11.1.4LUBRICATIONOil Capacity (from dry): 4 Liters1st DrainAfter a 50kmrunning-inDrain FrequencyEach MeetingViscosity75W140- Particular PrecautionsNo additives should be added to the oil. The resultingconsequences are not in any circumstances covered bySupercar Lites.When topping up the rear differential oil, do not mix any otheroil with that already in the box.Refill capacity may be lower than the dry capacity listed above.Overfilling will result with oil breather ta
SuperCar Lites User Manual Rev.02 7.4 SUSPENSION SETTINGS Rebound Set-Up Use a 3 mm allen key or tool. Turn the adjuster clockwise to fully closed position (position zero [0]). Turn counter clockwise to set the adjuster to recommended number of clicks. If you want to change setting, adjust in steps of 2-3 clicks at a time. Focus on the main adjuster. Main adjuster has 5-40 clicks range .
The Rt. Rev. George N. Hunt The Rev. Frederick K. Jellison The Rev. Dn. Ida R. Johnson The Rev. Michaela Johnson The Rev. Paul S. Koumrian The Rev. Canon Harry E. Krauss * The Rev. H. August Kuehl The Rev. Richard T. Laremore * The Rev. Donald A. Lavallee The Rev. Canon John E. Lawrence The Rev. Dr. Gary C. Lemery * The Rev. Dn. Betsy Lesieur *
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NACE Rev. 1.1 (ISIC Rev. 3) codes are often linked with more than one NACE Rev. 2 (ISIC Rev. 4) code. For example, 323 NACE Rev. 1.1 is linked with 261, 263 and 264 NACE Rev. 2 codes; 261 NACE Rev. 2 is linked with only one part of 311, 312, 313, 321 and 323 NACE Rev. 1.1 codes. Thus, it is not possible to obtain full codes of NACE
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1912-1914 Most Rev. Edward Joseph Hanna 1939-1948 Most Rev. Thomas Arthur Connolly 1947-1962 Most Rev. Hugh Aloysius Donohoe 1948-1950 Most Rev. James Thomas O’Dowd 1950-1969 Most Rev. Merlin Joseph Guilfoyle 1637-1969 Most Rev. Mark Joseph Hurley 1967-1979 Most Rev. William Joseph McDonald 1970-1974 Most Rev. Norman Francis McFarland
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16 Rev. Michael Keller 1983 17 Rev. Cyril McDonnell 2000 19 Rev. Thomas Foudy 2019 21 Msgr. David Bushey 1994 21 Rev. Jose Izquierdo SJ 1997 22 Rev. Julian Bastarrica, OFM 1990 23 Rev. Harry Ringenberger 2016 29 Rev. John Lama 1994 Eternal rest grant unto them O Lord, And may perpetual light shine upon them.
