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null  User manual
5.2.4 2014 NO LIMITS RACING TECHNICAL REGULATIONS
Issue 1 – 21 November 2013
All machines competing in any 2014 NLR Races must comply with the 2014 No
Limits Racing regulations. These regulations are additional to the ACU Standing
Regulations as laid out in the ACU Handbook. All NLR Championships are for riders
who possess a valid ACU or SACU.
These are as follows and are correct as of the printing of these regulations but
which are subject to any amendments made by the ACU or NLR which will be
issued by means of an NLR Bulletin.
Engine and frame numbers must not have been tampered with or deleted. New,
unstamped components are admissible. Bikes without a frame number are
acceptable providing they were originally supplied for racing. Motorcycles must be
based upon bikes originally homologated for road use.
5.2.5 NLR TECHNICAL SPECIFICATIONS
Rules intended to permit changes to the homologated motorcycle in the
interest of equality and competitiveness.
EVERYTHING THAT IS NOT AUTHORISED AND PRESCRIBED IN
THESE REGULATIONS IS STRICTLY FORBIDDEN
All motorcycles must comply in every respect with all the requirements for
Road Racing as specified in the Technical Regulations, unless it is equipped
as such on the homologated machine.
5.2.5.1 Machine Specifications
All items not mentioned in the following articles must remain as originally
produced by the manufacturer for the homologated machine.
5.2.5.2 Engine configurations and Displacement capacities
Two classes of motorcycle are covered in this rule book.
NLR 600
Over 200cc up to 300cc 2 stroke 2 cyl (Proddy class only - 600 Junior)
Over 300cc up to 500cc 4 stroke 2 cyl (Proddy class only - 600 Junior)
Over 300cc up to 415cc 4 stroke 4 cyl (Proddy class only - 600 Junior)
Over 415cc up to 600cc 4 stroke 4 cylinders
Over 500cc up to 675cc 4 stroke 3 cylinders
Over 540cc up to 750cc 4 stroke water cooled 2 cylinders
Over 600cc up to 830cc 4 stroke air cooled 2 cylinders
Dispensation will be given for all models of the Kawasaki ZX6R (636cc) to allow it to
race in the 600cc 4 stroke 4 cylinder category.
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NLR 1000
Over 600cc up to 1000cc 4 stroke 4 cylinders
Over 675cc up to 1100cc 4 stroke 3 cylinders
Over 750cc up to 1200cc 4 stroke water cooled 2 cylinders
Over 830cc up to 1300cc 4 stroke air cooled 2 cylinders
The displacement capacities must remain at the homologated size.
Modifying the bore and stroke to reach class limits is not allowed.
5.2.5.5 Number Plate Colours
Unless authorised in the Supplementary Regulations or Final Instructions the
following colour combinations must be used for the front and side numbers:
250cc machines – Green background and white numbers
350cc machines – Blue background and white numbers
500cc machines – Yellow background and black numbers
600cc machines - White background and blue numbers or
Red background and yellow numbers
1000cc machines - Red background and white numbers or
White background and black numbers
5.2.5.6 Fuel
Fuel used must be available from normal road fuel stations with a maximum
102 RON. No additives are permitted.
5.2.5.7 Tyres
Tyres as per the 2014 Championship regulations with the exception of No
Limits Cup where slick tyres or tyres with a V or Z rating must be used. Only
tyres on general sale to the public will be permitted. The depth of tyre treads
must be at least 2.5mm over the whole of the tyre tread (pattern) width, at
pre race control.
The tyre must have an E mark or DOT (American Department of
Transportation) approval and the DOT number must appear on the tyre wall.
In all classes wet race tyres may be used and may be fitted to an extra set of
spare wheels.
5.2.5.8 Engine
5.2.5.8.1 Fuel injection systems/carburettor
Fuel injection systems/carburettor refers to carburettors, throttle bodies, fuel
injectors, variable length intake tract devices, fuel pump and fuel pressure
regulator.
The original homologated fuel injection system must be used.
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Bikes with carburettor systems must use them in an unmodified form,
however jetting can be changed.
The fuel injectors must be stock and unaltered from the original
specification and manufacture.
Throttle bodies intake insulators may be modified.
The injectors must be standard units as on the homologated motorcycle.
Bell mouths may be modified.
On Fuel Injected bikes the secondary vacuum slides may be fixed in the
open position
Butterfly cannot be changed or modified.
5.2.5.8.2 Cylinder Head
Cylinder head must be as homologated. The following modifications are
allowed:
1) Grinding of the cylinder head surface on the side of the gasket;
2) Modifications of the inlet and exhaust ports by taking off or adding
material (welding is forbidden);
3) Original homologated valves guides may be cut or modified, but only on
the intake or exhaust port side;
4) Polishing of the combustion chamber;
5) Original valve seats must be used, but modifications are allowed to the
shape;
6) Compression ratio is free, but the combustion chamber can be modified
only by taking material off.
It is forbidden to add any material to the cylinder head unless as described
above.
The combustion chamber may be modified.
Rocker arms (if any) must remain as homologated (material and
dimensions).
Standard valves, valve springs and valve spring retainers must be used.
5.2.5.8.3 Camshaft
The method of drive must remain as homologated.
The cam shaft must be standard.
The cam chain or cam belt tensioning device(s) are free.
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At the technical checks: for direct cam drive systems, the cam lobe lift is
measured; for non direct cam drive systems (i.e. with rocker arms), the
valve lift is measured.
5.2.5.8.4 Cam Sprockets or gears
Cam sprockets or cam gears must remain standard
5.2.5.8.5 Cylinders
Cylinders must remain as homologated.
Only the following modifications to the cylinders are allowed.Cylinder head
gasket surface may be machined to allow the adjustment of compression
ratio or resurfacing to repair a warped cylinder surface deck.
Homologated materials and castings for cylinders must be used. The
surface finish of the cylinder bore must remain as homologated.
Cylinder capacity must remain at the homologated size.
2 stroke machines only the original ports may be modified.
5.2.5.8.6 Pistons
Pistons must remain as homologated.
Polishing and lightening is not allowed.
5.2.5.8.7 Piston Rings
Piston rings must remain as homologated. No modifications are allowed.
5.2.5.8.8 Piston Pins and Clips
Piston pins and clips must remain as homologated. No modifications are
allowed.
5.2.5.8.9 Connecting Rods
Connecting rods must remain as homologated.
Polishing and lightening is not allowed.
5.2.5.8.10 Crankshaft
Crankshaft must remain as homologated without modification.
Polishing and lightening is not allowed.
Modifications of the flywheels are not allowed.
5.2.5.8.11 Crankcase/Gearbox and all other Engine Cases (i.e. ignition case,
clutch case)
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Crankcases must remain as homologated. No modifications are allowed
(including painting, polishing and lightening).
It is not allowed to add a pump used to create a vacuum in the crankcase.
If a vacuum pump is installed on the homologated motorcycle then it may
be used only as homologated.
Other engine cases must be made of the homologated material with the
exclusion of the lateral side covers. (see below)
Lateral (side) covers may be altered, modified or replaced. If altered or
modified, the cover must have at least the same resistance to impact as
the original one. If replaced, the cover must be made in material of same
or higher specific weight and the total weight of the cover must not be less
than the original one.
Engine case guards in the form of strengthened engine side covers may
be installed. These covers must be no lighter in weight than the standard
part.
All lateral covers/engine cases containing oil and which could be in contact
with the ground during a crash, may be protected by a second cover made
of composite material, type injection moulded nylon 6.6 long fibre
60%,carbon or Kevlar®, aluminium or steel plates and/or bars are also
permitted. All these devices must be designed to be resistant against
sudden shocks and must be fixed properly and all devices are fitted by
bolts onto the engine cover/case.
Holes may be added in dry clutch covers to allow additional cooling.
The countershaft cover may be removed.
The addition of a crankcase protector at the countershaft is allowed.
5.2.5.8.12 Transmission/Gearbox
Transmission/gearbox ratios must remain standard.
The number of gears must remain as homologated.
Primary gears must remain as homologated.
Quick-shift systems are allowed.
Countershaft sprocket, rear wheel sprocket, chain pitch and size can be
changed.
Chain guard as long as it is not incorporated in the rear fender may be
removed.
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5.2.5.8.13 Clutch
Clutch type (wet or dry) and the way of operation (by cable or hydraulic)
must remain as homologated.
Friction and drive discs may be changed.
Clutch springs may be changed.
The clutch basket (outer) may be replaced.
The original clutch assembly may be modified for back torque limiting
capabilities (slipper type).
It is allowed to change to an aftermarket clutch with back torque limiting
capabilities (slipper type).
No power source (i.e. hydraulic or electric) can be used for gear selection, if
not installed in the homologated model for road use. Human power is
excluded from the ban.
5.2.5.8.14 Oil Pumps, water pumps and Oil Lines
Modifications are allowed but pump housing, mounting points and oil feed
points must stay as original.
Oil lines may be modified or replaced. Oil lines containing positive pressure,
if replaced, must be of metal reinforced construction with swaged or treaded
connectors.
The internal parts of the water pump may be changed or modified. The drive
ratio may be changed. The external appearance must remain as
homologated.
5.2.5.8.15 Radiator and oil coolers
The radiator and its hoses may be changed only if they fit in the standard
location and do not require any modifications to the main frame or to the
fairings’ outer appearance.
Modifications to the existing oil cooler are allowed only if it does not require
any modifications to the main frame or to the fairings’ outer appearance. A
heat exchange (oil/water) can be exchanged by an oil cooler.
Radiator fan and wiring may be changed, modified or removed.
Additional oil coolers are not allowed.
Oil cooler must not be mounted on or above the rear mudguard.
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5.2.5.8.16 Air Box
The basic air box must remain as originally produced by the manufacturer on
homologated machine. The top face only can be removed or drilled through.
The air filter element may replaced.
The air box drains must be sealed.
All motorcycles must have a closed breather system. The oil breather line
must be connected and discharge in the airbox.
Ram air tubes or ducts running from the fairing to the air box may be
modified, replaced or removed. If tubes/ducts are utilized, they must be
attached to the original, unmodified air box inlets.
5.2.5.8.17 Fuel Supply
Fuel pump and fuel pressure regulator must remain the same as on the
homologated motorcycle.
The fuel pressure must be as homologated.
Fuel lines from the fuel tank up to the injectors (fuel hoses, delivery pipe
assembly, joints, clamps, fuel canister) may be replaced.
The fuel line(s) going from the fuel tank to the fuel injection system must be
located in such a way that they are protected from possible crash damage.
Quick connectors or dry brake quick connectors may be used.
Fuel vent lines may be replaced.
Fuel filters may be added.
5.2.5.8.18 Exhaust System
Exhaust pipes and silencers may be modified or changed. Catalytic
converters must be removed.
The number of final exhaust silencer(s) must remain as homologated. The
silencer(s) must be on the same side(s) of the homologated model.
For safety reasons, the exposed edge(s) of the exhaust pipe(s) outlet(s)
must be rounded to avoid any sharp edges.
Wrapping of exhaust systems is not allowed except in the area of the riders
foot or an area in contact with the fairing for protection from heat.
The noise limit for will be 105 dB/A (with a 3 dB/A tolerance after the race).
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5.2.5.8 Electrics and Switches
Connectors and switches are free.
5.2.5.9.1 Ignition/Engine Control System (ECU)
Spark plugs and plug caps and wires may be replaced.
Ignition/Engine control system (ECU) and its basic programming (Maps)
must remain standard. Revised fuel maps may be flash loaded or an add on
fuel module may be added to change fueling only. The engines RPM limit
must as standard on the original road homologated.motorcycle.
No additional electronics forming control systems will be allowed (i.e.
external ignition/fuel cut traction control systems, engine throttle blipper
servo motors, ignition expanders or injector modules).
5.2.5.9.2 Generator, alternator, electric starter
Generator may be modified, removed or replaced.
The electric starter must operate normally and always be able to start the
engine during the practices and race (including the parc ferme).
5.2.5.9.3 Additional Equipment
No additional electronic hardware equipment may be added (e.g. data
acquisition, computers, recording equipment).
The addition of a device for infra red (IR) transmission of a signal between
the racing rider and his team, used exclusively for lap timing, is allowed.
The addition of a GPS unit for lap timing/scoring purposes is allowed.
Telemetry is not allowed.
5.2.5.9.4 Wiring Harness
The wiring harness may be altered or replaced. Additional wiring harnesses
may be added.
Cutting of the wiring harness is allowed.
5.2.5.9.5 Battery
The size and type of battery may be changed and relocated.
5.2.5.10 Frame and Body
5.2.5.10.1 Frame Body, Instrument support and Rear sub-frame
Frame must remain as originally produced by the manufacturer for the
homologated machine.
Holes may be drilled on the frame only to fix approved components (i.e.
fairing brackets, steering damper mount, sensors).
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The sides of the frame-body may be covered by a protective part made of a
composite material. These protectors must fit the form of the frame.
Nothing else can be added or removed from the frame body.
All motorcycles must display a vehicle identification number on the frame
body (chassis number).
Engine mounting brackets or plates must remain as originally produced by
the manufacturer for the homologated machine.
Rear sub frame may be changed or altered, but the type of material
must remain as homologated, or of higher specific weight.
The Instrument support frame can be changed or altered.
Additional seat brackets may be added, non-stressed protruding brackets
may be removed if they do not affect the safety of the construction or
assembly. Bolt-on accessories to the rear sub-frame may be removed.
The paint scheme is not restricted but polishing the frame body or sub-frame
is not allowed.
5.2.5.10.2 Front Forks
Forks must either remain as originally produced by the manufacturer for the
homologated machine OR may be a pair of fork legs from another (NLR
eligible) model from the same motorcycle manufacturer.
Standard original internal parts of the forks may be modified or changed. No
aftermarket or prototype electronic ally-controlled suspensions can be used.
If original electronic suspensions are used, they must be completely standard
(any mechanical or electronic part must remain as homologated).
After market damper kits or valves may be installed.
Fork springs may be modified or replaced.
Fork caps may be modified or replaced to allow external adjustment.
Dust seal can be modified, changed or removed if the fork is totally oilsealed.
The original surface finish of the fork tubes (stanchions, fork pipes) may be
changed. Additional surface treatments are allowed.
The upper and lower fork clamps (triple clamp, fork bridges) must remain as
originally produced by the manufacturer on the homologated machine Or if
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an alternative set of forks are fitted (see front Forks) the upper and lower fork
clamps (triple clamp, fork bridges) that were orignally supplied for use with
those same forks.
Steering damper may be added or replaced with an aftermarket damper.
The steering damper cannot act as a steering lock limiting device.
5.2.5.10.3 Rear Fork (Swing arm)
The rear fork must remain as originally produced by the manufacturer for the
homologated machine. A chain guard must be fitted in such a way to reduce
the possibility that any part of the riders’ body must become trapped between
the lower chain run and the rear wheel sprocket.
Rear fork pivot bolt must remain as originally produced by the manufacturer
for the homologated machine.
Rear axle chain adjuster can be modified or changed.
Rear wheel stand brackets may be added to the rear fork by welding or by
bolts. Brackets must have rounded edges (with a large radius). Fastening
screws must be recessed. An anchorage system or point(s) to keep the
original rear brake caliper in place may be added to the rear swing-arm.
5.2.5.10.4 Rear Suspension Unit
Rear suspension unit can be changed or modified. The original attachments
of the frame and rear fork must be as homologated.
Rear suspension unit spring(s) may be changed.
No aftermarket or prototype electronic ally-controlled suspensions can be
used. If original electronic suspensions are used, they must be completely
standard(any mechanical or electronic part must remain as homologated).
Rear suspension linkage must remain as originally produced by the
manufacturer for the homologated machine.
5.2.5.10.5 Wheels
Wheels must either remain as originally produced by the manufacturer at the
time of sale into the dealer/distributor network for the homologated machine
or as specified below.
If alternative fork legs are used (see Front Forks) a front wheel from the
same model may be used as well.
Aftermarket aluminium wheels of the same diameter as the original road
machine may also be used.
Any inner tube (if fitted) or inflation valves may be used.
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Wheel balance weights may be discarded, changed or added.
The speedometer drive may be removed and replaced with a spacer.
If the original design included a cushion drive for the rear wheel, it must
remain as originally produced for the homologated machine.
5.2.5.10.6 Brakes
Front and rear brake discs may be changed. The Brake swept area must be
the same or greater than standard.
Front Brake Master cylinders and levers can be changed.
Front Brake Calipers can be changed. The calipers must be designed to use
pads with a pad area that is the same or greater than standard.
Internally ventilated discs are not allowed if not homologated in the original
machine.
Replacement brake discs must be of ferrous material.
Rear brake calipers as well as all the mounting points and mounting
hardware (mount, carrier, hanger) must remain as originally produced by the
manufacturer for the homologated machine (see art 5.2.5.10.3) with the
exception of endurance where the the rear brake is free for the purpose of
quick release.
Rear master cylinder must remain as originally produced by the
manufacturer for the homologated machine
Front and rear hydraulic brake lines may be changed. Dry break connectors
are not permitted. The brake fluid reservoir may be replaced and/or
repositioned. The split of the front brake lines for both front brake calipers
must be made above the lower edge of the fork bridge (lower triple clamp).
Front and rear brake pads may be changed, their area must be the same or
greater than standard. Brake pad locking pins may be modified for quick
change type.
Additional air ducts are not allowed.
Endurance class only - Front and rear brake caliper bolts must be lockwired
5.2.5.10.7 Handle Bars and Hand Controls
Handle bars, throttle assembly and associated cables, hand controls and
levers may be replaced (does not include brake master cylinder).
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Handle bars and hand controls may be relocated.
Throttle controls must be self-closing when not held by hand
Electric starter switch and engine stop switch must be located on the handle
bars.
5.2.5.10.8 Foot Rest/Foot Controls
Foot rest/foot controls may be relocated, but the original mounting points
must be used.
Foot rests may be rigidly mounted or a folding type which must incorporate a
device to return them to the normal position.
The end of the foot rest must have at least an 8mm solid spherical radius.
Non folding footrests must have an end (plug) which is permanently fixed,
made of aluminum, plastic, Teflon® or equivalent type of material (min.
radius of 8mm). The plug surface must be designed to reach the widest
possible area of the footrest. The Chief Technical Officer has the right to
refuse any plug not satisfying this safety aim.
5.2.5.10.9 Fuel Tank
Fuel tank must remain as originally produced by the manufacturer for the
homologated machine.
Fuel tanks with tank breather pipes must be fitted with non-return valves that
discharge into a catch tank with a minimum volume of 250 cc made of a
suitable material.
Fuel caps may be changed. Fuel caps when closed, must be leak proof.
Additionally, they must be securely locked to prevent accidental opening at
any time. Any part, which could be in contact with the ground during a crash,
may be protected by a second cover made from composite materials, type
carbon fibre or Kevlar®.
5.2.5.10.10 Fairing/Body Work
a) Fairing and body work may be replaced. The material may be changed.
The Chief Technical Officer has the right to refuse any bodywork that
does not appear safe and cosmetically tidy.
b) Wind screen may be replaced, transaprent or ‘light tint’ is allowed, the
rider must be able to see easily through it.
c) The original combination instrument/fairing brackets may be replaced. All
other fairing brackets may be altered or replaced.
d) The original air ducts running between the fairing and the air box may be
altered or replaced.
e) The original air ducts into the airbox may be altered or replaced.
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f) The lower fairing has to be constructed to hold, in case of an engine
breakdown, at least half of the total oil and engine coolant capacity used
in the engine (minimum 5 litres). The lower edge of openings in the
fairing must be positioned at least 50 mm above the bottom of the fairing.
g) Minimal changes are allowed to permit the use of an elevator (stand) for
wheel changes and to add a small plastic protective cone to the frame or
engine.
h) Front mudguard may be replaced. The use of carbon fibre or Kevlar®
composites is allowed.
i) Front mudguard may be spaced upward for increased tyre clearance.
j) Rear mudguard fixed on the swing-arm may be replaced. The use of
carbon fibre or Kevlar® composites is allowed.
k) The existing rear mudguard under the seat may be removed. A
mudguard may be fitted directly onto the swing-arm (it may not cover
more than 120 degrees of the wheel).
5.2.5.10.11 Seat
Seat, seat base and associated body work may be replaced.
The top portion of the rear body work around the seat may be modified to a
solo seat.
Holes may be drilled in the seat or rear cowl to allow additional cooling.
Holes which are bigger than 10mm must be covered with metal gauze or fine
mesh. Mesh must be painted to match the surrounding material.
The appearance from both front rear and profile must conform in principle to
the homologated shape.
All exposed edges must be rounded.
5.2.5.10.12 Fasteners
Standard fasteners may be replaced with fasteners of any material and
design.
Aluminum fasteners may only be used in non-structural locations.
Titanium fasteners may be used in structural locations, but the strength and
design must be equal to or exceed the strength of the standard fastener it is
replacing.
Special steel fasteners may be used in structural locations, but the strength
and design must be equal to or exceed the strength of the standard fastener
it is replacing.
Fasteners may be drilled for safety wire, but intentional weight-saving
modifications are not allowed.
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Fairing/body work fasteners may be changed to the quick disconnect type.
5.2.5.11 The following items MAY BE altered or replaced from those fitted to
the homologated motorcycle
Any type of lubrication, brake or suspension fluid may be used.
Bearings (ball, roller, taper, plain, etc.) of any type or brand may be used.
Gaskets and gasket materials.
Painted external surface finishes and decals.
Tachometer – NB this must be working so that noise limits may be measured
5.2.5.12 The following items MAY BE removed
Emission control items (anti-pollution) in or around the air box and engines
(O2 sensors, air injection devices)
Speedometer and related wheel spacers.
Bolt on accessories on a rear sub frame.
5.2.5.13 The Following Items MUST BE removed
- Headlamp, rear lamp and turn signal indicators (when not incorporated in
the fairing). Openings must be covered by suitable materials.
- Rear-view mirrors.
- Horn.
- License plate bracket.
- Tool box.
- Helmet hooks and luggage carrier hooks
- Passenger foot rests.
- Passenger grab rails.
- Safety bars, centre and side stands must be removed (fixed brackets must
remain).
5.2.5.14 The following items MUST BE altered
Motorcycles must be equipped with a functional ignition kill switch or button
mounted at least on one side of the handlebar (within reach of the hand while
on the hand grips) that is capable of stopping a running engine.
It is recommended that machines be equipped with a red light on the
instrument panel. This light must flash in the event of oil pressure drop.
All drain plugs must be wired. External oil filter(s) screws and bolts that enter
an oil cavity must be safety wired (i.e. on crankcases, oil lines, oil coolers,
etc.)
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All motorcycles must have a closed breather system. The oil breather line
must be connected and discharge in the airbox.
Where breather or overflow pipes are fitted they must discharge via existing
outlets. The original closed system must be retained, no direct atmospheric
emission is permitted.
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