Mazda Global MX-5 Cup User manual

Long Road Racing, Global MX-5 Cup User Guide, Version 1.3, 3-8-17 age 1 of 26
Global MX-5 Cup User Guide, Version 1.3
Refer to the latest version of the Global MX-5 Technical Rules for up to date information regarding rules and regulations
Do Not Operate Ve icle until you’ve done t e Following:
• Read t is entire document, all associated manufacturer instructions, and FIA Safety Regulations.
• Fully installed a FIA seat, FIA safety belts and FIA Drivers Nets.
• Connected t e Fire Bottle Wiring in t e Trunk and Activated t e Fire System
Contents
1.0 Starting the Car and Operation of Cooling umps ............................................................................................................ 2
2.0 To Start the Engine: ........................................................................................................................................................... 2
3.0 To Turn the Engine Off: ..................................................................................................................................................... 2
4.0 Fire System: ....................................................................................................................................................................... 2
5.0 Seat Installation: ............................................................................................................................................................... 3
6.0 Seat Belt Installation: ........................................................................................................................................................ 4
7.0 Fluids: ................................................................................................................................................................................ 4
8.0 Engine, Transmission and Differential Seals: .................................................................................................................... 5
9.0 Auxiliary ower: ................................................................................................................................................................ 5
10.0. AiM MXL2 Dash: ............................................................................................................................................................. 6
11.0 Ballast Box: ...................................................................................................................................................................... 6
12.0 Baseline Setup: ................................................................................................................................................................ 6
13.0 Dampers: ......................................................................................................................................................................... 7
14.0 Front Sway Bar Settings .................................................................................................................................................. 9
15.0 Basic Handling Guide ...................................................................................................................................................... 9
16.0 Basic Service Intervals: .................................................................................................................................................... 9
16.1 Transmission and Differential Filter Service: ............................................................................................................ 10
17.0 Wiring Diagrams: ........................................................................................................................................................... 12
17.1 ower Distribution anel (Trunk) .............................................................................................................................. 12
17.2 Main Chassis Harness (Trunk to Dash) ...................................................................................................................... 13
17.3 Switch anel and Start Button (Dash) ....................................................................................................................... 14
17.4 Engine Bay (Cowl and Alternator Relay) ................................................................................................................... 15
17.5 Fire Bottle Wiring Harness Layout ............................................................................................................................ 16
18.0 Nut and Bolt: ................................................................................................................................................................. 17
19.0 Torque Specifications: ................................................................................................................................................... 17
19.1 Front Suspension ....................................................................................................................................................... 18
19.2 Front Brakes .............................................................................................................................................................. 19
19.3 Rear Suspension ........................................................................................................................................................ 20
19.4 Rear Brakes ............................................................................................................................................................... 21
19.5 Engine Bay ................................................................................................................................................................. 22
19.6 Under Car .................................................................................................................................................................. 24
19.7 Differential and Transmission ................................................................................................................................... 25

Long Road Racing, Global MX-5 Cup User Guide, Version 1.3
age 2 of 26
1.0 Starting the Car and Operation of Cooling Pumps
•Check Oil and Coolant levels before starting the vehicle.
•The Switch panel on the dash has the following 3 Switches and 1 Button:
1. 3-Way Master:
a. Down “Off” = ower Off
b. Middle “ACC” = Accessory ower On
c. Up “IGN” = ACC + Ignition ower
2. Separate transmission & differential cooler pump and fan over ride switches:
a. Down = ower Off
b. Up = ower On
3. Fire Bottle Button ( ress to Operate Fire Bottle)
Figure 1: Switc Panel Figure 2: Start Button
2.0 To Start the Engine:
•With the Key in the car, move the 3-Way Master Switch to the IGN position (figure 1). Depress Clutch edal (and
brake as needed), ress the Factory Start Stop Button. (figure 2)
3.0 To Turn the Engine Off:
•Move the 3-Way Master Switch to the OFF osition. Or, flip the external master kill switch on the cowl near the
Windshield Wipers.
4.0 Fire S stem:
•Before vehicle use, the Fire Bottle Cable, see figure 3, must be reconnected to the bottle in the trunk. This line is
disconnected during transport to eliminate any possibility of accidental discharge.
Figure 3. Fire Bottle Cable, Trunk.
Fire Bottle
Cable

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age 3 of 26
•The control unit, see figure 4, on the center console has a switch that allows you to:
oTest the battery
oTest the system (when the system is in TEST, you can operate the trigger buttons without discharging the
system)
oEngage or Arm the system.
Figure 4: Fire System Control Unit, Rig t Side of Center Console.
•Review the LifeLine instruction booklet included in the trunk kit, or online at http://www.lifeline-fire.co.uk/
•!!! Always remember to TEST and ARM (or engage) t e system prior to on track activity!!!
5.0 Seat Installation:
•Before vehicle use, a FIA compliant Seat and seat mounting brackets must be installed meeting the requirements
of FIA document, 2016 Appendix J – Article 253, Safety Equipment (Groups, N,A, R-GT), ART. 16, Seats, Anchorage
oints and Supports. This document is available for download at http://www.fia.com/Regulations.
•An FIA compliant seat mounting baseplate, see figure 5, Mazda part # 0000-08-5111, is provided as a mounting
surface.
oAdditional lates may be welded to the provided seat mount plate to extend the mounting surface
forward if necessary. lates must be between 1/8” and 3/16” thick, must be attached by at least 2.75” of
1/8” weld, and may not be added for the purpose of ballast.
Figure 5: Seat Mount Base Plate

Long Road Racing, Global MX-5 Cup User Guide, Version 1.3
age 4 of 26
6.0 Seat Belt Installation:
•Before vehicle use, FIA compliant Safety Belts must be installed meeting the requirements given in FIA document,
2016 Appendix J – Article 253, Safety Equipment (Groups, N,A, R-GT), ART. 6, Safety Belts. This document is
available for download at http://www.fia.com/Regulations. FIA compliant safety belts, eyebolts and backing
plates are supplied with the vehicle.
•A bar for shoulder belt attachment, see figure 6, is provided in the rear of the car. Additional brackets may be
welded to this bar, and this bar only, to achieve desired belt angle. All connection points must be designed to
withstand 1,470 daN (3,405 lbs-force) per the FIA Safety Equipment Specification, 2016 Appendix J – Article 253,
Safety Equipment (Groups, N,A, R-GT), ART. 6, Safety Belts.
Figure 6: S oulder Belt Bar
7.0 Fluids:
Item GMX5 Spec Fluid
Engine Oil 5w30 Castrol Syntec European Blend
Rear Differential Oil 75W90 Castrol Syntrax
Transmission Oil 75W90 Castrol Syntrax
Brake Fluid
Castrol SRF
Fuel
91
–
101 Octane Series dependent
Coolant
Cool
-
aide
•The vehicles are shipped with stock Engine Coolant to prevent freezing during shipment. A bottle of Maxima Cool-
Aide is included in the Trunk Kit for use in competition which should only be mixed with distilled water.
•All testing has been done with standard 93 octane premium gasoline.
•Fuel pump out: MUST HAVE MANNED FIRE EXTINGISHER
o1) Connect quick release fuel line at fuel fitting
Shoulder Belt Bar

Long Road Racing, Global MX-5 Cup User Guide, Version 1.3
age 5 of 26
o2) Toggle fuel pump relay to activate fuel pump
8.0 Engine, Transmission and Differential Seals:
•The Engine, Transmission and Differential have been sealed with tamper proof/evident devices to prevent
modification to these parts. Evidence of removal or tampering with these seals will be cause for disqualification
and or fines in Global MX-5 Cup Competition.
•Open testing can be done with unsealed components, however for official Global MX-5 Cup ractice, Qualifying
and Races, only sealed components may be used.
9.0 Auxiliar Power:
•The main power panel is mounted in the trunk of the car.
There is a 6 way fuse block available for powering
Accessories such as helmet blowers, cool suits, etc. The
fuse block is rated at 30 amp for an individual connection,
with a 65 amp max for all 6 branches combined. All
connections made to this block will need to be insulated.
See figure 7.
Figure 7: Power Distribution Panel (Trunk)
•There is also a standard 12volt Accessory Socket located under the dash just to the right of the center console that
may be used. See figure 8.
Figure 8: 12 volt Accessory Socket Location

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age 6 of 26
10.0. AiM MXL2 Dash:
•The vehicle is equipped with an AiM MXL2 Dash. The MXL2 connects to the vehicle through the OBDII ort for
power and CAN Communication.
•Before your vehicle shipped, the MXL2 was updated with the latest firmware and a standard configuration
template. lease check for updates on the AiM website on a regular basis.
•Tracks can be uploaded to the MXL2 using AiM’s G S Manager Software.
•The MXL2 instruction booklet is included in the trunk kit. User instructions and links for Downloads of the Race
Studio 3 and G S Manager software can also be found here:
ohttp://www.aim-sportline.com/eng/products-car/mxl2/index.htm
11.0 Ballast Box:
A standard Ballast Box, Mazda part # 0000-08-5053 that mounts in place of the passenger seat is included. Ballast may be
added to the vehicle using a Right Side Seat Mount late, an empty Ballast Box with no lid, an empty Ballast Box with the
lid, or a Ballast box with 5 and 10 pound plates as needed.
•Ballast Box, empty with the Lid and all fasteners, 27.5 lbs / 12.5 kg
•The Ballast Box will hold up to an additional 130 lbs / 59kg of ballast. Twelve 12 lbs plates and two 5 lbs plates.
•10 ound / 4.53kg ( art Number 0000-08-5128-10) and 5 ound / 2.27kg ( art Number 0000-08-5128-05) weights
designed to fit in the box are available for purchase.
•Secure all ballast plates inside the box with two ½” nuts, and secure the lid with the four ½” bolts provided.
•Ballast may not be installed anywhere on the vehicle except inside the ballast box.
•The Ballast Box has tabs on each of the four sides to allow for items such as cool suit units to be strapped in place.
12.0 Baseline Setup:
This vehicle has been shipped with a standard ride height and sway bar end link lengths that will need to be adjusted after
your seat and ballast is installed.
To set initial balance:
•Disconnect front and rear sway bars and place vehicle on scales with ballast and driver weight in place.
oThe minimum weight of the vehicle with no fuel with driver is 2415 lbs. or 1095 kg. Use the ballast box
and ballast plates described above to add ballast as needed to achieve the minimum weight with driver.
The ballast box must remain in the car, extra weight(s) are optional.
•Adjust ride heights by raising or lowering the spring perches on the dampers to achieve target cross weight %.
oThe minimum ride height is 4” excluding the 2 plastic angles in front of the front tires, see figure 9, which
attach to the front bumper cover and inner fender liners (see picture below). The recommended ride
height would be 4-3/8” at the lowest part of the vehicle.
Figure 9: Plastic Angles Excluded from Ride Heig t Measurement
o50.5 % Right Cross ercentage ((RF Weight + LR Weight) / Total Weight) is a recommended starting point,
though this will vary by track and driver preference.
lastic Angle Excluded from Ride
Height Measurement

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age 7 of 26
•Once desired ride height and cross weight % is achieved, set the sway bars to neutral by adjusting the end link
lengths such that the sway bar can be reconnected without loading it.
•After the desired weight distribution is achieved, align your vehicle. Recommended Toe Settings are 1.5mm out
on both front tires (3mm out total) and 1mm in on each rear tire (2mm in total). A very good starting point for
camber is 2.8 degrees in the front and 3.0 degrees in the rear.
13.0 Dampers:
•The vehicle is equipped with 2-way adjustable Dynamic Suspension Spool Valve (DSSV) dampers by Multimatic.
oFront Damper is Mazda art Number 0000-04-5616
oRear Damper is Mazda art Number 0000-04-5617
•The Dampers adjust 0 through 11 for Compression (Bump, Blue) and (Rebound, Red) using a square ended 4mm
Allen key.
oIt is important that you do not use a ball end Allen key to make these adjustments, this could cause the
Allen key receiver to strip out. A correct 4mm Allen key is provided in the Trunk kit.
oAn increase in the valve setting causes an increase in compression or an increase in rebound.
oWe recommend starting in the center, 5 Compression / 5 Rebound and adjusting from there as needed.
oNote that there is a stop pin that prevents the valve from continuously rotating See figure 10.
Figure 10: Damper Valve wit Seal. 5 Compression, 6 Rebound S own
•The spring perches are manufactured with a 68mm hex design for adjustment and locking. A pair of 68mm
Damper erch Wrenches are needed to lock and unlock the perches to make ride height adjustments.
oThe 68mm Damper erch Wrenches are available for purchase from Mazda Motorsports,
art # 0000-04-5620
•To service the Torrington bearing, the bottom clevis must be removed. A 36mm Damper Body wrench is needed
to hold the clevis while loosening and tightening the nut.
oThe 36mm Damper Body Wrench is available for purchase from Mazda Motorsports, art # 0000-04-5621
•Dynamic Suspension by Multimatic will make available their SpecFinder
TM
Software that is a fully predictive
computerized simulation that precisely models the hydraulic flow of the DSSV damper spool valves. This can be
used to help better understand the magnitude of changes made with valve adjustments. More information on
this tool will be provided in 2016.
•The Damper valve block is sealed with a tamper proof label. Evidence of removal or tampering with these seals
will be cause for disqualification and or fines in Global MX-5 Cup Competition. Valve work may only be done
through Long Road Racing in conjunction with Mazda Motorsports and Multimatic.
Stop in

Long Road Racing, Global MX-5 Cup User Guide, Version 1.3
age 8 of 26
Figure 11: Typical Force Vs. Velocity Front Damper
Figure 12: Typical Force Vs. Velocity Rear Damper

Long Road Racing, Global MX-5 Cup User Guide, Version 1.3
age 9 of 26
14.0 Front Swa Bar Settings
•The Front Sway Bar has three available stiffness settings: Stiff, Medium and Soft. The vehicle is delivered with the
bar set at the recommended Medium setting.
•To soften the sway bar, disconnect the end links, adjust the lengths and spacer configurations as needed to
reconnect the link to the outermost hole on the sway bar arm.
•To stiffen, disconnect the end links, adjust the length and spacer configuration as needed to reconnect the link to
the inner-most hole on the sway bar arm.
•Changes must be made to both the left and right connections to achieve the stiffening or softening affect. See
figure 13.
Figure 13: Sway Bar End Link Settings
15.0 Basic Handling Guide:
Front Rear
Comp /
Bump Rebound
Comp /
Bump Rebound
Straig t line braking - front lockup
-
Straig t line braking - rear lockup
+ -
Trail braking - Slow turn-in response
+ +
Trail braking - Understeer
- +
Trail braking - Oversteer
+ -
Turn in (no braking) - Understeer
- +
Turn in (no braking) - Oversteer
+ -
Steady State Turning - Understeer*
- - + +
Steady State Turning - Oversteer*
+ + - -
Corner exit - Understeer
- +
Corner exit - Oversteer
+ -
Straig t line accel - lack of traction
- -
* Steady state = no damper influence

Long Road Racing, Global MX-5 Cup User Guide, Version 1.3
age 10 of 26
16.0 Basic Service Intervals:
As with any standard service items, these intervals should be adjusted based on your level of use and special on-track
conditions. The service intervals are based on 10-12 events per year, with a typical event weekend having approximately
3 hours of track time.
FLUIDS
SPEC FLUID
AFTER EACH
EVENT
EVERY OTHER EVENT
ANNUALLY
Engine Oil
5
w30 Castrol Syntec
Replace
Differential Oil
75w90 Castrol Syntrax
Replace
Transmission Oil
75w90 Castrol Syntrax
Replace
Brake Fluid
Castrol SRF
Bleed
Full Flush
Engine Coolant
Maxima Kool Aid
W/Distilled Water Full Flush
FILTER
MAZDA PART NUMBER
AFTER EACH EVENT
EVERY OTHER EVENT
ANNUALLY
Engine Oil
Filter
E01
-
14
-
320A
Replace
Transmission Filter
000
-
08
-
5032
Service
Replace
Differential Filter
000
-
08
-
5032
Service
Replace
Intake Air
Filter
EES
-
13
-
3A0
Replace
CHASSIS PART
AFTER EACH EVENT
REPLACE
Hub Bearing (front/rear)
Clean and Inspect
Bi Annually
Tie Rod End (left/right)
Clean and Inspect
Annually
Eccentric Bolts
Clean and Inspect
Annually
Rear Axles
Clean and Inspect
Annually
Engine Mounts
Clean and Inspect
Annually
Drive Shaft
Clean and Inspect
Annually
Rear Upright (left/right)
Clean and Inspect
Annually
Rear Suspension (left/right)
Clean and Inspect
As needed
Upper Control Arm (left/right)
Clean and Inspect
Annually
Lower Control Arm (left/right)
Clean and Inspect
Annually
Wheels
Clean and Inspect
As Needed
Sway Bars (front/rear)
Grease Front Bushings
As Needed
Drop Links Front (left/right)
Clean and Inspect
Annually
Drop Links Rear (left/right)
Clean
and Inspect
Annually
Brake Duct (left/right)
Clean and Inspect
As Needed
Torrington Bearings
Clean and Lube
As Needed
Dampers
Clean and Inspect
As Needed
Fire Bottle
Check Battery/Bottle ressure
As Needed
Safety Equipment
Clean and Inspect
See
Service Date
16.1 Transmission and Differential Filter Service:
The filter body is labeled “IN” and “OUT”, see figure 14, to indicate fluide flow direction through the filter. Note the
direction of flow and ensure the filter is reinstalled in the same orientation. The Transmission and Differential umps

Long Road Racing, Global MX-5 Cup User Guide, Version 1.3
age 11 of 26
have an arrow showing the direction of fluid flow, see figure 15, these must agree with the flow direction of the filters.
Fluid will not flow through the filter in the opposite direction and you will damage your transmission or differential.
To Service the Inline Filter:
•Remove filter body and disassemble as shown in figure 16.
•Clean out any debris and reassemble.
•Reinstall in correct orientation as described above.
Figure 14: Transmission and Differential Cooler Line
Filter, Assembled
Figure 16: Transmission and Differential Cooler Line
Filter, Disassembled.
Figure 15: Transmission and Differential Cooling Pump

Long Road Racing, Global MX-5 Cup User Guide, Version 1.3, 3-8-17 age 12 of 26
17.0 Wiring Diagrams:
17.1 Power Distribution Panel (Trunk)

Long Road Racing, Global MX-5 Cup User Guide, Version 1.3, 3-8-17 age 13 of 26
17.2 Main Chassis Harness (Trunk to Dash)

Long Road Racing, Global MX-5 Cup User Guide, Version 1.2, 2-1-16 age 14 of 26
17.3 Switch Panel and Start Button (Dash)

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17.4 Engine Ba (Cowl and Alternator Rela )

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17.5 Fire Bottle Wiring Harness La out

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18.0 Nut and Bolt:
•Despite the extensive Quality rocesses in place during the manufacturing of your vehicle, it is highly
recommended and general good practice with any race car, to do a full nut and bolt check on the car before first
use, and in between on-track sessions.
19.0 Torque Specifications:
This list is not comprehensive. For items not listed consult the 2016 MX-5 Service Manual from Mazda.
1 Front Suspension
# of
Fasteners
Torque Spec
ft-lbs
Front Upper control Arm 2 40-47
Front Lower Damper Bolt 1 40-47
Front Upper Damper Nut 3 37-43
Front Hub 3 91-100
2 Front Brakes
Front ABS Sensor 1 71-88 in-lbs
Front Caliper 2 59-74
Front Brake Line Banjo Bolt 1 110 in-lbs
Front Brake Bleeders 4 107-141 in-lbs
3 Rear Suspension
Rear hub 3 91-100
Rear Axle Nut 2 175-202
Rear Damper Top Mount Nut 2 34-40
Rear Damper Lower Bolt 1 49-59
4 Rear Brakes
Rear Brake Caliper Bracket 2 38-48
Rear Brake Caliper 2 15-18
Rear ABS Wheel Speed Sensor 1 71-88 in-lbs
Front Brake Line Banjo Bolt 1 110 in-lbs
Rear Brake Bleeders 2 54-70 in-lbs
5 Engine Bay
Strut Tower Brace Center 2 12-19
Strut Tower Brace (Damper Nuts L& R) 6 37-43
Header Nuts 5 32-47
Motor Mount Lower 3 25-33
Motor Mount Upper 3 22-29
Motor Mount Upper Nut 1 24-30
Oil Filter Sandwich late Nut 1 35
6 Under Car
Tunnel Member "X" Brace 4 14-19
Member Bracket 4 14-19
7 Differential and Transmission
Diff Bracket Top 4 40-51
Diff Bracket Sides (Mount Rubbers) 2 40-51
Rear Subframe rimary 6 78-92
Drive Shaft ( ropeller Shaft) 4 37-43
ower lant Framework Differential End 4 121-147
ower lant Framework Transmission End 4 100-120
8 W eels 16 80

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19.1 Front Suspension

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19.2 Front Brakes

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19.3 Rear Suspension