Mazda Global MX-5 Cup User Manual
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 Vehicle until you’ve done the Following:
•
Read this entire document, all associated manufacturer instructions, and FIA Safety Regulations.
•
Fully installed a FIA seat, FIA safety belts and FIA Drivers Nets.
•
Connected the Fire Bottle Wiring in the Trunk and Activated the Fire System
Contents
1.0 Starting the Car and Operation of Cooling Pumps ............................................................................................................ 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 Power: ................................................................................................................................................................ 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 Power Distribution Panel (Trunk) .............................................................................................................................. 12
17.2 Main Chassis Harness (Trunk to Dash) ...................................................................................................................... 13
17.3 Switch Panel 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
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1.0 Starting the Car and Operation of Cooling Pumps
Fire Bottle
Cable
• 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” = Power Off
b. Middle “ACC” = Accessory Power On
c. Up “IGN” = ACC + Ignition Power
2. Separate transmission & differential cooler pump and fan over ride switches:
a. Down = Power Off
b. Up = Power On
3. Fire Bottle Button (Press to Operate Fire Bottle)
Figure 1: Switch 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 Pedal (and
brake as needed), Press the Factory Start Stop Button. (figure 2)
3.0 To Turn the Engine Off:
• Move the 3-Way Master Switch to the OFF Position. Or, flip the external master kill switch on the cowl near the
Windshield Wipers.
4.0 Fire System:
• 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.
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Figure 3. Fire Bottle Cable, Trunk.
• The control unit, see figure 4, on the center console has a switch that allows you to:
o Test the battery
o Test the system (when the system is in TEST, you can operate the trigger buttons without discharging the
system)
o Engage or Arm the system.
Figure 4: Fire System Control Unit, Right 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) the 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
Points 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.
o Additional Plates may be welded to the provided seat mount plate to extend the mounting surface
forward if necessary. Plates 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
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Brake Fluid
Castrol SRF
Fuel 91 –
101 Octane Series dependent
Coolant
Cool
-
aide
Shoulder Belt Bar
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: Shoulder 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
• 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
o 1) Connect quick release fuel line at fuel fitting
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o 2) 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 Practice, Qualifying
and Races, only sealed components may be used.
9.0 Auxiliary 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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10.0. AiM MXL2 Dash:
Plastic Angle Excluded from Ride
• The vehicle is equipped with an AiM MXL2 Dash. The MXL2 connects to the vehicle through the OBDII Port for
power and CAN Communication.
• Before your vehicle shipped, the MXL2 was updated with the latest firmware and a standard configuration
template. Please check for updates on the AiM website on a regular basis.
• Tracks can be uploaded to the MXL2 using AiM’s GPS Manager Software.
• The MXL2 instruction booklet is included in the trunk kit. User instructions and links for Downloads of the Race
Studio 3 and GPS Manager software can also be found here:
o http://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 Plate, 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 Pound / 4.53kg (Part Number 0000-08-5128-10) and 5 Pound / 2.27kg (Part 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.
o The 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 %.
o The 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 Height Measurement
o 50.5 % Right Cross Percentage ((RF Weight + LR Weight) / Total Weight) is a recommended starting point,
though this will vary by track and driver preference.
Height Measurement
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• Once desired ride height and cross weight % is achieved, set the sway bars to neutral by adjusting the end link
Stop Pin
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.
o Front Damper is Mazda Part Number 0000-04-5616
o Rear Damper is Mazda Part Number 0000-04-5617
• The Dampers adjust 0 through 11 for Compression (Bump, Blue) and (Rebound, Red) using a square ended 4mm
Allen key.
o It 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.
o An increase in the valve setting causes an increase in compression or an increase in rebound.
o We recommend starting in the center, 5 Compression / 5 Rebound and adjusting from there as needed.
o Note that there is a stop pin that prevents the valve from continuously rotating See figure 10.
Figure 10: Damper Valve with Seal. 5 Compression, 6 Rebound Shown
• The spring perches are manufactured with a 68mm hex design for adjustment and locking. A pair of 68mm
Damper Perch Wrenches are needed to lock and unlock the perches to make ride height adjustments.
o The 68mm Damper Perch Wrenches are available for purchase from Mazda Motorsports,
Part # 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.
o The 36mm Damper Body Wrench is available for purchase from Mazda Motorsports, Part # 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.
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Figure 11: Typical Force Vs. Velocity Front Damper
Figure 12: Typical Force Vs. Velocity Rear Damper
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