Radical Sportscars SR5 User manual

SR5
RadicalSportscars
SR5
RadicalOwnersManual

RadicalMotorsportLtd
24IvattWayBusinessPark
Westwood
Peterborough
PE37PG
info@RadicalSportscars.com
www.RadicalSportscars.com
DearRadicalOwner
ManythanksforpurchasingaRadicalSR5sportscar.
Whetheryouintendrunningyourcarattrackdays,enteringitinsprintsandhillclimbs,orcompetinginthe
widerangeofcircuitracingavailabletoyou,onethingremainsconstant.Awell‐maintainedandprepared
sportscarwillensurethatyougetthemaximumperformanceandreliabilitythatRadicalisrenownedfor
theworldover.
Radicalshavecoveredhundredsofthousandsoftrackday,testdayandracingmiles.Thismanualhighlights
manyofthelessonsandtipswehavelearned.Donotstartyourcaruntilyouhavereadit.
YourRadicalhasbeendesignedwithoneobjective–togiveyoutheultimatedrivingpleasure!
Happydriving
Mick Hyde
MickHyde
ForRadicalMotorsportLtd
Sales
T:+44(0)1733331616
F:+44(0)1733264959
sales@RadicalSportscars.com
TechnicalSupport/Parts
T:+44(0)1733331717
F:+44(0)1733264959
technical@RadicalSportscars.com
Accounts
T:+44(0)1733331818
F:+44(0)1733269668
Accounts01@RadicalSPortscars.com
Powertec(Engine)
T:+44(0)1733331919
Figure1‐RadicalSR5atDubaiAutodrome(September2007)
F:+44(0)1733269479
info@PowertecEngineering.com
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SR52007RadicalOwnersManual.docx–issue1‐22/11/07‐3‐Issued:21/09/06
CONTENTS
PREPARATIONFORSHAKE‐DOWN..........................................................................................................................................4
DRIVINGPOSITION..............................................................................................................................................................4
CHECKALLFLUIDLEVELS.......................................................................................................................................................5
STARTINGTHEENGINE.........................................................................................................................................................5
RUNNINGTHEENGINE..........................................................................................................................................................5
GEARBOX...........................................................................................................................................................................7
STANDARDSR5GEARRATIOS...............................................................................................................................................7
FLAT‐SHIFT........................................................................................................................................................................8
PNEUMATICPOWERSHIFT....................................................................................................................................................8
BEDDING‐INBRAKES............................................................................................................................................................8
FUEL.................................................................................................................................................................................8
DASHBOARD.......................................................................................................................................................................9
REVINDICATOR...................................................................................................................................................................9
CENTRE‐LOCKHUBNUTS.....................................................................................................................................................9
AIRJACKS..........................................................................................................................................................................9
GENERALSETUPPROCEDURE–FLATPATCH...........................................................................................................................10
SUSPENSIONGUIDE–DRYSETUP........................................................................................................................................10
STEERINGRACKSETUPPROCEDURE....................................................................................................................................11
RIDEHEIGHT....................................................................................................................................................................11
CORNERWEIGHTS..............................................................................................................................................................11
BRAKEBIASSETTINGS........................................................................................................................................................12
GENERALCARPREPARATION...............................................................................................................................................12
DRIVINGTECHNIQUE.........................................................................................................................................................12
SR5DECALDESIGNSHEET..................................................................................................................................................13
RACE/TESTHISTORY........................................................................................................................................................14
COMPONENT‘LIFING’CHART–...........................................................................................................................................15
INTRAXDAMPERINFORMATION..........................................................................................................................................16
3wayadjustabledamperInformation.....................................................................................................................16
Compressionadjustment:.........................................................................................................................................16
Reboundadjustment:................................................................................................................................................16
InTraxdampers‐springchart...................................................................................................................................17

PREPARATIONFORSHAKE‐DOWN
Beforetakingtothetrack,itisimportantthatyoucarryoutathoroughspannercheck,payingparticular
attentiontoallhoses,connectionsandsuspensionfixings,brakebiasetc.
Theoillevelmustbecheckedusingthedipsticksupplied.Thelevelmustbemaintained
betweenthetoptwomarkswhenhot,andbetweenthebottomtwo
markswhencold.ThelevelshouldbecheckedAFTERrunningthe
engine,andholdingtherevsat3,000rpmfortenseconds,toallow
theoiltobescavengedback.Theengineshouldbeturnedoff,to
checkthelevel.
RadicalrecommendSilkoleneProRsynthetic‐basedracingoil(or
similarifthisbrandisnotavailable).
Warning
Donotrevtheenginemorethan3,000rpm(oneyellowlightonthe
dash)untiltheoiliswarm.Whencoldtheoilcanrunat100psi,which
maydamagetheoilcooler.
Inthebrakeandclutchmastercylinders,useonlyhightemperatureracingbrakefluid.
Theenginecoolingsystemusesa50:50anti‐freeze/watermixture.Thelevelshouldbetothetopofthe
swirlpot.
DRIVINGPOSITION
Thecombineddriverandpassengerseatmaybeadjustedforwardandbackwardtosuitindividualdrivers.
Pleasenote:Theseatbeltcrutchstrapwillalsoneedadjusting.
Thepositionofthepedalscanalsobeadjustedbya)adjustingthepedalface,b)adjustingthepedalangle
andc)bymovingthepedalpivotshaft.Pleasenotethatc)willrequirechangingthemastercylinderpush‐
rods.
IfyourSR5isfittedwithaPowertecPS2pneumaticpowershifter,pleaserefertotheseparate
manufacturersoperatinginstructions.
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CHECKALLFLUIDLEVELS
•Checkthatoilisvisibleintheoiltank.(Theexactlevelcanonlybecheckedoncetheengineiswarm–
seestartingprocedure.)
•Checkthebrakeandclutchreservoir.
•Checkthatcoolantlevelistothetopoftheswirlpot.
RECOMMENDEDLUBRICANTS&FLUIDS
Engineoil:SilkoleneProR15/50(orsimilar)
Gearbox:useSilkoleneBOA90LSlimited‐slipgearoil
MasterCylinders:SilkoleneProrace2000brakefluid(DOT4orsimilar)
Fuel:98octaneunleadedor100octaneracefuel(CAM2or108octaneintheUS)
Coolant:50/50mixtureofwater/anti‐freeze
STARTINGTHEENGINE
1. AlwaysstarttheenginewithalaptopconnectedtotheECUsothatallengineparameterscanbe
monitoredduringwarm‐up.
2. Checkoilisvisibleinoiltank.Checkwaterlevelinswirlpot.Theactualoilleveldoesnotmatteratthis
point,becauseanamountofoilhasdrainedbackintotheengine–thisreturnstothetankwhenthe
engineisstarted.
3. Crankenginetogetoilpressurewithignitioncoilsdisconnected.
4. Connectcoilsandturnignitionon.Startenginewithnothrottle,letengineidleatapproximately2,000‐
3,000rpm.Checkoilpressureisat60psiminimum.
5. Whenenginewatertemperaturereaches50°C,revengineseveraltimestoover3,000rpmandturnoff.
6. Immediatelycheckoillevelwithdipstick.
RESTARTINGPROCEDURE
1. Ideally,theengineisstarted45minutespriortogoingontrack.Turnoffwhenthewatertemp.reaches
85°Candallowheattosoakintotheengine.Restart10minutesbeforegoingontrackandgetthe
temperatureto75°C.
2. Theoillevelshouldbecheckedeveryhourofrunninganditshouldbetoppeduptothelevelindicated
above.
RUNNINGTHEENGINE
Donotruntheengineunderloadif:‐
a) oiltemperatureisbelow60°C
b) oiltemperatureisabove120°C
c) watertemperatureisbelow60°C
d) watertemperatureisabove100°C
e) oilpressurewhenuptotemperatureat4,000rpmisunder50psi.

Theoilpressurewhentheengineisstartedfromcoldshouldrunat90psiat4,000rpm.Whenupto
temperaturetheoilpressureshouldread60psiat4,000rpm.
Maximumenginerevs:‐8,600rpm
Therevlimiterissetto8,600rpm.Persistentuseoftherevlimiterwilldamagetheengine.
Theengineoilandfiltershouldbechangedeverysix(6)hoursofrunning.
Donotattempttoadjustslowrunningspeed,oranyotherengineparameterwithoutalaptopconnectedto
theECUrunningthecustomerversionofLIFESystemssoftware(availablefromPowertec).
Itisimportanttologthenumberofhourstheengineisrun.Theengineshouldrunfornomorethan30
racinghoursbeforebeingreturnedtothefactoryforarebuild.Iftheengineisstressedless(i.e.trackday
orroaduse)thecarshouldbereturnedtothefactoryevery30hoursforarollingroaddynamometertest.
Engineswhicharenotraced,regularlycover90hourswithoutrequiringattention(providingtheyarenot
over‐revved.Particularcareandattentionshouldbepaidtothedown‐shifts).
Note:Intheeventthattheenginestalls,theignitionmasterswitchmustbeturnedoffandthenonagain
(afteratwoseconddelay)toresettheECU.
Figure2RadicalSR5atMagnyCours
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GEARBOX
GEARBOXMAINTENANCE
TheSR5issuppliedwithaHewlandJFRsix‐speedsequentialtransaxle.Hewlandtransaxlesshouldhavethe
crownwheel/pinionandgeardogsinspectedforsignsofwearaftereveryevent.(Refertothe
manufacturersmanualforinspectionandrepairprocedures.)
Crownwheeel&pinion:12:34
Crownwheel&pinionratio:2.833:1
GEARING
RatiosintheSR5arenotcontrolled,socananmaybechangedtosuitdifferentcircuits.The‘short’set
listedbelowisanoptionfortightertracks(i.e.BrandsHatch).Agearratiochartforcalculatingsuitable
ratiosisavailableat:www.hewland.com.PleaserefertoHewlandgearboxmanualor
website:www.hewland.comforchanginggearratios.
STANDARDSR5GEARRATIOS
FORCARSBUILTBEFORE16/11/2007
GearPartno.:Ratio
1stCS‐1608‐12:352.917
2ndFTR‐15:33‐HUB2.200
3rdFTR‐17:31‐STD1.824
4thFTR‐15:25‐STD1.667
5thFTR‐17:25‐STD1.471
6thFTR‐18:24‐STD1.333
FORCARSBUILTAFTER16/11/2007
SR5Ratios–16”rearwheels1
GearShort
(optionfortighttracks)
Long
(fittedasstandard)
1st12:38
68mph
12:38
68mph
2nd14:33
91mph
14:33
91mph
3rd15:29
111mph
16:30
108mph
4th15:26
122mph
17:27
135mph
5th17:27
136mph
17:25
147mph
6th16:24
143mph
18:25
154mph
1Revlimitsetto8,500rpm
SR5Ratios–13”rearwheels2
GearShort
(optionfortighttracks)
Long
(fittedasstandard)
1st12:35
65mph
12:35
65mph
2nd15:34
84mph
15:33
87mph
3rd15:27
106mph
17:30
108mph
4th16:25
121mph
16:24
128mph
5th19:27
134mph
18:24
144mph
6th18:24
142mph
21:26
153mph
2Revlimitsetto8,200

SEQUENTIALGEARCHANGE–HEWLANDJFR
TheSR5issuppliedwiththegearselectionsetto“pullleverbacktoshiftupthebox”and“pushlever
forwardtoshiftdownthebox”.Toengageneutralfrom1stgearliftthelevergentlyontherighthandside
oftheseatandpushthegearleverforwardonce,tofindreversepushforwardagainwiththesmalllever
stilllifted.TheorderisR,N,1,2,3,4,5,6.
GEARBOXOIL
Withoilcooler:2.2litres
Withoutoilcooler1.7litres
FLAT‐SHIFT
IfyourSR5isfittedwithaflat‐shiftsystem,theclutchneednotbeoperatedgoingupthegearbox.
PNEUMATICPOWERSHIFT
IfyourSR5isfittedwithaPowertecpneumaticpaddle‐actuatedpowershiftsystem,pleaserefertothe
manufacturersoperatinginstructions.
BEDDING‐INBRAKES
Thecarcomesfittedwithcarbonmetallicbrakepads.Tobedinthebrakesandachievemaximumstopping
power,afilmofcarbonmustbetransferredtothediscs
Gentlyapplybrakes6to8timesatmediumspeed.Increasespeedtosimulateraceconditions,andapply
brakeshardafurther6to8times.
Allowbrakestocoolfor15minutes.Donotapplybrakeswhilststationaryduringcoolingdownperiod.
UseonlyRadicalrecommendedbrakepads.
FUEL
TunedenginesintheUSAshouldonlyberunonracingfuelsuchascam2,oraminimumof108octane.We
doNOTrecommendmixingoctaneboosterswithpumpfuel.
WARNING
Thefuelfilterwillrequirechangingaftertheinitialrun.Itislocatedtotheleftoftheengine.

DASHBOARD
REVINDICATOR
Yellow3‐4–5,Green6‐7–8,Red8.2–8.5
*Temperaturesarenotdisplayeduntilthefluidsreach45°C.
Whenignitionisswitchedon,thedashrunsthroughatestdisplay.
Hightemperaturesorlowpressureswilltriggeralargewarninglightadjacenttothegaugeitisindicating.
Withignitionon,pressthedatabuttontoshowmaximumrevstodate(lasttwodigitsnotshown).The
maximumrecordedrevsdisplaymayberesetbythefactory,orbyanapprovedRadicaldistributor.
CENTRE‐LOCKHUBNUTS
AnodisedREDforleft‐handside,
AnodisedBLUEforright‐handside.
TorqueSetting–200ftlbs
AIRJACKS
Carsfittedwithairjacksaresuppliedwithanairlance,whichisinsertedintoavalveattherearofthecar.The
lancerequiresconnectiontoabottledairsupply,andthepressureshouldberegulatedto250‐300lb
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GENERALSETUPPROCEDURE–FLATPATCH
1. checkscalesareflatandzeroed
2. disconnectanti‐rollbars
3. reset(zero)shocksabsorbers
4. settyrepressures
5. checkfrontpushrodsareequallength
6. checkfrontspringpre‐loadissetcorrectly
7. ballastcarfordriver
8. setrideheight(procedurebelow)
9. setcambers
10. settoes
11. setcornerweightsbyadjustingrearspringplatforms(ensuretheyarenotpre‐loaded).
12. re‐connectanti‐rollbars,ensuringtheyhavenopre‐load
13. resetshockabsorberstocentresettings
14. removeballast
15. checkthatfrontdiffuserislevel,bothfront‐to‐rearandleft‐to‐right,andissettothecorrectground
clearance
SUSPENSIONGUIDE–DRYSETUP
Thecarissetupatthefactorybut,thefinalsettingsshouldbearrivedatbytestingfortheparticular
driver’spreferenceandtheparticularcircuit.Trytocheckthetyretemperaturesforbalanceacrossthe
contactpatchwithinoneminuteofafastlap.Theinsideedgecanbe10°‐15°higherthantheouteredge
onradialplyslicktyres.
Front:
RideHeight:85mm
Diffuserheight:55mm
(min)
Pre‐load(no.ofturns):6
Shocksettings:Avo:6
Intrax:centreofrange
Tyrepressure(Dunlop):Hot:24‐28psi
Cold:16‐18psi
Springrate:7”×300lb
Camber: ‐2½°to‐3½°
Toein:2mm‐3mm
overall
Nik‐link:Medium
Rear:
RideHeight:75mm
Pre‐load(no.ofturns):0
Shocksettings:Avo:8
Intrax:centreofrange
Tyrepressure(Dunlop):Hot:24‐28psi
Cold:16‐18psi
Springrate:7”×350lb
Camber:‐2°to‐3°
Toein:2mm‐3mm
Nik‐link:medium
Note:Measuretherideheightatfrontofthechassisandattheseatbackbulkhead,(belowrolloverbar)
withthedriverseatedandthreegallonsoffuelinthetank.

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STEERINGRACKSETUPPROCEDURE
Tomakesureyoursteeringrackissetcorrectlyandrunningfreelywehavesetoutasimplesetup
procedure.
1. Loosenthetop16mmAllenscrewandlocknutcompletely.
2. Loosenthefour6mmAllenscrewsaroundthesteeringinputshaftandrotatetheknurledring
anticlockwisetoloosenthesteeringrackshaft.
3. Thesteeringrackshaftshouldnowbefreetorotateintherackhousing.Turntheknurledring
clockwisewhilerotatingtherackinthehousingbackandforthuntilallthemovementhasgone,with
therackcorrectlyadjustedyoushouldbeabletofeelatinyamountofrotationalmovement,tighten
thefour6mmAllenscrews.
4. Tightenthetop16mmAllenscrewuntiljusttightandbackoffoneAllenkeyflat,tightenthelocknut.
5. Therackinnowsetcorrectlyandshouldmovefreelyfromsidetosidewithnotightspots.
RIDEHEIGHT
Therideheightmayneedincreasingwhencarryingapassenger.
CORNERWEIGHTS
Formaximumperformance,theRadicalshouldhavethecornerweightsaccuratelysetwiththedriverinsitu.
Theprocedureisasfollows:‐
1. Positionthecaronaflat,horizontalsurface.
2. Equalisealltyrepressurestohotsetting,say28psi.
3. Takeallreadingswithdriverincar,orequivalentweightintheseat.
4. RemoveboltfromoneendofthefrontandrearNik‐Link,andadjustshockstofullsoft.
5. Setrideheightfront&rear,thencamberfront&rearandfinallytoe‐infront&rear.
6. Putcaronweightscales,andsetcornerweightsbyadjustingspringplatforms*.Itisusuallydifficultto
achieveidenticalsettingsoneachcornertowithin10%.Ensurethatthesumofthediagonalweights
areasnearaspossible.
*Whenusingpre‐load,adjustablepushrodsareusedtosetrideheightandcornerweights
7. Re‐checkrideheightandsplitterheightwiththebodyon.
8. Lockspringplatforms.
9. RefitNik‐Links,rearanti‐rollbars,resetshocks,removedriverorsimilarweight,andreducetyre
pressures.
10. Youarenowreadyto“rock&roll”.

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Note:Ifyouintendcarryingapassengerforthemajorityofthetime,theaboveprocedureshouldbe
carriedoutwithhim/herinthecar.
BRAKEBIASSETTINGS
Setcentraltotwoturnstowardsfront(clockwiseonthedashadjuster).Furtheradjustmentcanbemade
tosuitindividualcircuitsandtyreconfigurations.Adjustbiastotherearinwetconditions.
GENERALCARPREPARATION
TokeepyourRadicallookingatitsbestthefibreglassandcarbonfibreitemscanbequicklyandeffectively
cleanedwithpolish,whileallchassis,suspensionandpanelpartscanbekeptlookingnewandcorrosion‐free
bywipingthemdownwithaclothsprayedwithWD40.
DRIVINGTECHNIQUE
Ifyouareunfamiliarwithasequentialshiftcar,itisrecommendedthatyouchangegearusingtheclutchwhen
goingbothupanddownthegearbox.Onceyouhavebecomefamiliarwiththetechnique,changinggear
goinguptheboxcanbeachievedbyliftingthethrottleslightlyandsimultaneously‘snicking’thegearin,
withoutdepressingtheclutch.Ondown‐changesitisimperativethedriverdepressestheclutchandraises
theenginespeedbeforeengagingthegear.Smoothgearchangescanbebestachievedbyusingthe‘heeland
toe’technique.Onlychangedownonegearatatime.
Aswithanydog‐engagementgearbox,aggressivegearchangeswilldamagethegeardogswhichwillresultin
gearengagementproblems.Onlyuseamaximumof6,000–7,000rpmwhilegettingusedtodrivingyourSR5.
Ifyouaccidentallydown‐changeinsteadofanup‐changeyouarelesslikelytoover‐revtheengine.Ifyoudo
over‐revtheengine,makeyourwayslowlybacktothepitsandchecktheyellowrecallbuttononthedash.If
youhaverevvedtheengineover9,000rpm,switchoffandreturntheenginetoPowertecforinspection
immediately.
Ensurethatthetyresandbrakesarefullyuptotemperaturebeforepushinghard.
TheRadicalSR5hasphenomenalbrakingperformanceandwillcarryconsiderablespeedintoacorner.
Practicebrakinghard,butcomeoffthebrakessmoothlyandconcentrateoncarryingspeedintoacorner.On
exitingthecorner,thethrottleshouldbefedinprogressively.
Drivingsmoothlyisthesecrettoquicklaptimes.
Onefinaltip:CHECKYOUROILLEVELBEFOREEVERYRUN!TheSR5canpullover2.5gwhencornering.Ifyoudonot
havethecorrectoillevel,evenwithadrysumpmotor,youriskstarvingtheengineofoil,withexpensive
consequences.

SR5DECALDESIGNSHEET
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RACE/TESTHISTORY
DateCircuitConditionsQualPosnFastestLap
TimeResultTimeon
Circuit
:
:
:
:
:
:
:
:
:
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:
:
:
:
:
:
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:

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COMPONENT‘LIFING’CHART–
Astheperformanceofourcarsincreasesandthenumberofhoursracingthecarscompletegrows,weare
abletomoreaccuratelypredictthelifespanofacar’scomponents.Pleaseseebelow,therevised‘Radical
ComponentLifespanChart’.
Thechartgivestherecommendedlifeexpectancyofcomponentsunder‘normal,on‐trackracingconditions’.
Ifsomeofyourracingtimeisdone‘off‐track’oryouhitkerbs,potholesorothercars–hard,thenyouwill
needtoconsideringreducingthetimescalesrecommended.Ontheotherhand,more‘gentle’trackdayuse
willobviouslyextendtherecommendedtime!
Onenewadditiontothelististhewingsupportstays,thelifeoftheseisgreatlyshortenedifthewingisused
topush,andparticularlypullthecararoundinthepitlane,garagesandtrucks.Itworksperfectlytosupport
thewingandthedownforcegeneratedinthedirectionintended,andnotatanangletothecentre‐lineofthe
vehicle.
COMPONENTHOURSACTION
Engine 30 Rebuild
Gearbox 10Inspect
Gearbox 30 Rebuild
SuspensionBushes 30Replace
SuspensionRoseJoint 30 Replace
FrontUprightincludingHub 50Replace
FrontWishbones 60 Inspect/replace
RearUpright 50Replace
RearHub 50 Replace
RearWishbone 60Inspect/replace
DriveShafts 30 Replace
Calipers 60Rebuild
BrakeDiscs 10 Inspect/replace
ShockAbsorbers 60Rebuild
SteeringRack 50 Inspect/rebuildorreplace
BrakeMasterCylinder 60Inspect/replace
WingSupportStays 60 Inspect/replace
FuelTank remove&inspectannually
Ifyouownanddrivethecar,butdonotprepareorrunityourself,itisyourresponsibilitytobesurethat
theengineerwhodoeshasacopyofthismanual,andhasreadit.

INTRAXDAMPERINFORMATION
3WAYADJUSTABLEDAMPERINFORMATION
Alltheadjustmentsworkindependentlyallowingyoutofindtherightset‐up.
(1) Redadjusteroncanister:‐High‐speedcompression,50clicksturnclockwiseformoredamping.
(2) Small4mmscrew:‐Lowspeedcompression,18clicksturnclockwiseformoredamping.
(3) Blackadjusteronspindleeye:Rebound,turnclockwiseformoredamping.
(3)
(2)
(1)
COMPRESSIONADJUSTMENT:
HIGHSPEED:
1. Itcontrolsfastcorners.Whendampingrateisincreasedthecarfeelslikeithasgotstrongersprings.
2. Increasestep‐by‐step5clicksatthetime,thefine‐tuningbyoneclick.
3. Rain:open+/‐10clicksfrombestdrysetting.
LOWSPEED:
4. Itcontrolsrollinthecarandwillhelptomakethetyresworkingwhenthereislessgrip.
5. Increasestep‐by‐step1‐2clicksatthetime.
6. Rain:open+/‐2clicksfrombestdrysetting.
REBOUNDADJUSTMENT:
REBOUND:
Front:Byfindingtherightset‐upyoucandialoutundersteer,duringtesting5clicksatthetime.
Rear:Formaximumtraction,don’tgooverthetop,keeptherearmoving.
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INTRAXDAMPERS‐SPRINGCHART
PartNo. Length
(mm)
Rate
(N/mm)
Rate
(lbf/in)
SP00180120685
SP00280140799
SP00380150857
SP004100110628
SP005100120685
P006100130742
SP007100140799
SP008100150857
SP009100160914
SP010100170971
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