RPE GSX-R 1300S User manual

Radical Performance Engines GSX-R Engine Operation Manual
Version 4 - 18.12.14

Specifications ..........................................................................................1
Installation ..............................................................................................1
Rear Engine Brace ...............................................................................1
Oil System................................................................................................1
Coolant System ...................................................................................1
Fuel......................................................................................................1
Octane Boosters..................................................................................1
RPE –Quaife Gear Drive System.........................................................1
Types of Oil Systems ...............................................................................1
Oil Type Number 1 - Blanking Plates, No Jet.......................................2
Oil System Number 2 - Oil cooler fittings and jet ...............................2
Oil System 3 –Oil Cooler Fittings and Bung........................................3
Oil System 1 Diagram - Cast Sump Pan……………………………………………5
Oil System 1 Diagram - Billet Sump Pan…………………………………..………6
Oil System 2 & 3 Diagram…………………………………..…………………………..7
Engine Management...............................................................................7
MBE - Radical Easimap Setup Screen..................................................7
Life Racing - PTMon.............................................................................7
Throttle and Airbox installation..............................................................8
Airbox..................................................................................................8
Fluid Levels and Temperatures...............................................................8
Coolant Temperature..........................................................................8
Coolant Level.......................................................................................8
Oil Temperature –both Wet and Dry Sump Systems.........................8
Wet Sump Oil Level.............................................................................8
Dry Sump Oil Level ..............................................................................8
Starting Procedure……………………………………………………………………………10
Re-Starting ..........................................................................................9
Service Intervals......................................................................................9
Engine Oil and Oil Filter ...................................................................... 9
Oil Filter Fitting Procedure .............................................................9
Fuel Filter............................................................................................ 9
Air Filter ..............................................................................................9
Engine Returns...................................................................................... 10
Balancing Throttle Bodies on a 4 cylinder ............................................11
Life Racing ECU .................................................................................11
MBE ECU...........................................................................................12
Instructions For Retrieving Data from Life ECU and Data logger.........13
Driving Techniques for Cars with an RPE Engine..................................14
Contact Details...................................................................................... 15
Contents

1
Specifications
•GSX-R 1300S
•GSX-R 1300T
•GSX-R 1350T
•GSX-R 1340T
•GSX-R 1400T
•GSX-R 1500
•GSX-R 1550T
•GSX-R 1585T
•GSX-R 1600T
•GSX-R 1300 Turbo
•GSX-R 1615T
•GSX-R SS 1500
Rated Speed –10,500 rpm
Firing Order –1, 2, 4, 3.
Cylinder 1 is on the left hand side of the engine (Generator side).
Installation
The engine should be mounted into the chassis by means of four bolts into
the mounting points on each side of the cylinder head and two bars through
the horizontal rear mountings in the crankcases above and below the
gearbox through the rear engine Brace. See next Page for Rear Engine Brace
fitting procedure.
Ensure no looms or hoses are trapped between the engine and chassis.
All sensors should be connected correctly and in working order, including:
•Air charge temperature
•Crank Position Sensor
•Oil pressure
•Fuel Pressure (if applicable)
•Coolant temperature
•Throttle Position Sensor
•Oil temperature
•Barometric sensor
•Cam Phase Sensor (if
applicable)
The oil system must be connected as per the information in this operation
manual. Please read this document carefully, there are different types of oil
system fitted to RPE 4 cylinder engines. Please ensure the correct oil system
is used. There is more information on the various oil systems on pages 2 to 7.
PLEASE BE AWARE THAT FITMENT OF AN INCORRECT OIL
SYSTEM COULD CAUSE AN ENGINE FAILURE AND WILL
INVALIDATE YOUR ENGINE WARRANTY.
The coolant system must be connected and capable of providing adequate
cooling to maintain the correct operating temperatures outlined later in this
document.
Please contact RPE if you have any questions concerning the installation of
your engine. Contact details are listed on page 16.

1
REAR ENGINE BRACE
Dear Radical owner, mechanic or distributor,
Your engine has been returned with a supporting brace on the rear of the engine:
In order to fit your engine you will need to modify the rear engine cradle by removing a boss as shown:

1
Oil System
Recommended –Silkolene PRO R or PRO 4 15W-50
PRO R/4 is a unique, fully synthetic lubricant for ultimate engine protection
and superior clutch and gearbox operation for high performance 4 stroke
motorcycle engines.
If this specific oil is not available to you, please use a comparable
oil.
NEVER USE CAR ENGINE OIL IN A MOTORCYCLE ENGINE. THE INTEGRAL
GEARBOX WITHIN THE MOTORCYCLE ENGINE WILL SHEAR THE MOLECULES
IN THE OIL. ALSO, MOTORCYCLE ENGINES HAVE INTEGRAL WET CLUTCHES.
Coolant System
50% water and 50% antifreeze/summer coolant.
Fuel
RPE Suzuki engines should be run on a minimum of Super Unleaded 98 RON,
or 100 octane race fuel.
Tuned engines in the USA should be run on racing fuel such as Cam2 or a
minimum of 108 Octane.
Octane Boosters
If fuel of the correct octane level is not available then octane boosters can be
used, please contact RPE before using octane boosters in fuel.
RPE –Quaife Gear Drive System
Recommended Oil –Shell Helix Racing Gear Oil 75W-90
Shell Helix Racing Gear Oil 75W-90 is a synthetic gear oil designed to provide
optimum protection under extreme load conditions, whilst maintaining high
efficiency.
Oil Systems Variations
Due to a number of different oil cooling systems in circulation, the oiling
system must be confirmed before the engine is installed.
Oil System Number 1: 2 blanking plates installed on the engine oil cooler inlet
and outlet ports and the oil jet behind the oil filter is removed.
Oil System Number 2: -8 or -10 oil cooler fittings on the engine oil cooler inlet
and outlet ports, and the oil jet behind the oil filter has a 3mm hole drilled in
it.
Oil System Number 3: -8 or -10 oil cooler fittings on the engine oil cooler inlet
and outlet port. A blanking bung is installed behind the oil filter, in place of
the oil jet.
•On later model engines, that are fitted with a cast type sump pan,
there is only one type of oil system regardless of installation. One
blanking plate on the oil cooler inlet port and the oil jet behind the oil
filter is removed.
•If you are unsure as to the specification of your previous engine, RPE
can provide you with the necessary information.
•An RPE technician can also confirm the specification for you if an
engine exchange is to take place at a race meeting.
•If in any doubt please Phone or Email
Tel [phone]
Email [e-mail] or
[e-mail]
Fluids

2
Oil Type Number 1 - Blanking Plates, No Jet
This type of oil system can be used with both RPE cast (Silver) and billet
(Gold) dry sump pans.
The restrictor jet behind the oil filter is also removed. The oil return pipe
from the scavenge pump goes through the oil cooler (or water to oil heat
exchanger) before returning to the oil tank.
Cast Sump
Jet Location
If the engine is fitted with a cast sump pan, there will be no blanking plate on
the sump pan, just one on the engine.
Billet Sump
Jet Location
Blanking plates are fitted to the engine’s OEM oil cooler in and outlet ports.
IMPORTANT
When this oiling system is used, the jet behind the filter must be removed.
IF THIS IS NOT DONE IT WILL RESULT IN ENGINE FAILURE.

3
Oil System Number 2 - Oil cooler fittings and jet
This system can only be used with RPE billet dry sump pans.
Jet with 3mm diameter hole
There are two fittings on the engine oil cooler inlet and outlet ports, they are
either -8 or -10. In this case there is a restrictor jet with a 3mm hole located
behind the oil filter. The oil returning from the scavenge pump is pumped
directly back to the oil tank.
IMPORTANT
When using this oiling system, the jet behind the filter must have a hole
drilled in it.
IF THIS IS NOT DONE IT CAN RESULT IN ENGINE FAILURE.
Oil System 3 –Oil Cooler Fittings and Bung
This system is mainly used on the Radical SR4, as they have long hoses that
run to and from the oil cooler due to the radiator being mounted further
away from the engine than normal
Blanking Bung
There are two fittings on the engine oil cooler inlet and outlet ports, they are
either -8 or -10. In this case there is a blanking bung behind the oil filter. The
oil returning from the scavenge pump is pumped directly back to the oil tank.
IMPORTANT
When using this oiling system, the jet behind the filter has no hole drilled, it
is a solid bung.
IF THIS IS NOT DONE IT CAN RESULT IN ENGINE FAILURE.

4
Oil System 1 Diagram –Cast Sump Pan
Breather Pot Connection
To dry sump tank
FROM UNION ON TOP OF
ENGINES BREATHER POT
Radical Performance Engines GSX-R Oil System –2008 Onwards
This is for an RPE Hayabusa Engine with a cast sump pan.

5
FROM UNION ON TOP OF
ENGINES BREATHER POT
Oil System 1 Diagram –Billet Sump Pan
Breather Pot Connections
To dry sump tank
Radical Performance Engines GSX-R Oil System
This is for an RPE Hayabusa Engine with a billet sump pan.
FROM UNION ON TOP OF
ENGINE BREATHER POT

6
Oil System 2 & 3
To engine breather tank
To dry sump tank
This is for an RPE Hayabusa engine with a billet sump pan.
Radical Performance Engines GSX-R Oil System –Pre 2008
Radical Performance Engines GSX-R Oil System Pre 2008
This is for an RPE Hayabusa Engine with a billet sump pan.
Breather Pot Connections