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. 1 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. 2 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. 3 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) 4 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. 5 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. 6 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). 7 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). 8 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 9 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. 10 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). 11 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. 12 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. 13 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.) 14 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. 15
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