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2015 US Open Spec Honda Technical Regulations (Version 1.1) US OPEN Spec Honda Technical Regulations (2015-‐V1.1) 1 www.MAXSpeedEntertainment.com Table of Contents Categories and Kart Numbers ..........................................................................................................3 Amount of Equipment ......................................................................................................................3 Engine Declaration Procedures ..........................................................................................3 Chassis Declaration Procedures .........................................................................................3 Kart ...................................................................................................................................................3 Chassis ................................................................................................................................3 Bodywork ...........................................................................................................................4 Tires ..................................................................................................................................................4 Tires/Wheels ....................................................................................................................................4 Data Acquisition ...............................................................................................................................4 Composite Materials ........................................................................................................................5 Safety of Equipment .........................................................................................................................5 Helmets ..............................................................................................................................5 Helmet Support ..................................................................................................................5 Suits ....................................................................................................................................5 Fuel/Oil .............................................................................................................................................5 Legal Additions .................................................................................................................................5 Technical Specification .....................................................................................................................5 Modification .......................................................................................................................5 Cylinder Head .....................................................................................................................6 Cylinder ..............................................................................................................................6 Cylinder Length ..................................................................................................................6 Piston Assembly.......................................................................................................................................... 6 Piston Ring .........................................................................................................................6 Crank, Rod, and Assembly ..................................................................................................7 Transmission ......................................................................................................................7 Clutch .................................................................................................................................7 Engine Cases ......................................................................................................................7 Exhaust ...............................................................................................................................7 Sound Emission ..................................................................................................................7 CDI ......................................................................................................................................7 Stator/Flywheel ..................................................................................................................8 Stator .................................................................................................................................8 Coil .....................................................................................................................................8 Carburetor ..........................................................................................................................8 Air Box/Air Filter ................................................................................................................8 Reed Cage, Manifold, and Reeds .......................................................................................8 Gaskets, Bearings, and Seals ..............................................................................................9 Water Pump .......................................................................................................................9 Cooling Fluid ......................................................................................................................9 Fuel Pumps .........................................................................................................................9 Radiators ............................................................................................................................9 Spark Plug ..........................................................................................................................9 Scoring Transponder ........................................................................................................................9 Cameras ...........................................................................................................................................9 Ballast ...............................................................................................................................................9 Chain Guards ..................................................................................................................................10 US OPEN Spec Honda Technical Regulations (2015-‐V1.1) 2 www.MAXSpeedEntertainment.com 1.
Categories and Kart Numbers: 1.1. Same digit numbers will not be allowed and letters will not be recognized. All karts must have a different kart number and will be organized by class. Please see the following for the kart number choices per class. SPEC HONDA Junior: SPEC HONDA Senior: SPEC HONDA Elite: SPEC HONDA Master: •
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201 -‐ 299 301 -‐ 399 01 -‐ 99 500 -‐ 599 600 – 699 Amount of Equipment: For each race event (from non-‐qualifying practice to the final) maximum following amount of equipment is allowed: • 1 chassis • 2 sets of dry tires + 1 front + 1 rear spare tire o
2 sets of dry race tires can be used at anytime once qualifying has begun • 2 sets of wet tires + 1 front + 1 rear spare tire o
2 sets of rain race tires can be used at anytime once a rain race has been declared by race officials • 2 engines The equipment allowed is from the official sessions posted on the event schedule, to the final race. Tires and Chassis may be specified in the supplemental regulations. The Engine declaration procedures are as follows: If you declare 2 engines during your declaration time period, you may switch between the two declared engines at your convenience. If one of these engines has a mechanical failure you may not rebuild the engine and you must use your second declared engine. If both engines fail, you must get permission from the technical director on how to proceed. If you declare 1 engine during your declaration time period, you must only use that engine for the remainder of the event. If this engine has a mechanical failure you may replace the broken parts with no related penalty (under Technical Director Supervision), or you may declare a second engine with penalty. A shared engine form will be available for drivers that need to share an engine between competitors. This form must be completed for both drivers during your time declarations. That engine may be shared between both competitors at their convenience. However, once you have shared an engine neither competitor may add another engine regardless of mechanical failures. If an engine has a mechanical failure you must get permission from the technical director on how to proceed. •
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If you are late to declare your engine or engines, you will be penalized. If you are found using a non-‐declared engine during any official session you will be disqualified from that session with -‐additional penalty or fine possible. It is the intent to not allow changes from one cylinder group (’97 – ’99 early to ’00 -‐ ’02 late), to the other during a series. A competitor will need to register cylinder year during the drivers’ first declaration process. The Chassis Declaration procedures are as follows: You will be able to declare 1 chassis during the declaration time period. At no time may you be allowed to switch chassis, unless irreparable damage has occurred. • If your chassis has sustained irreparable damage you must get permission from the Technical Director to change chassis. • You will not be allowed to change brands during an event. •
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Kart: Chassis: • For the US Open any chassis approved by MSE is allowed. • Chassis tubing: round tubing only. US OPEN Spec Honda Technical Regulations (2015-‐V1.1) 3 www.MAXSpeedEntertainment.com •
Maximum diameter of rear axle = 50 mm, minimum wall thickness according to CIK-‐FIA rules. Any brake system must have a valid CIK-‐FIA homologation. Front brakes are required in all classes. All braking systems must be operated by a single foot pedal; unless, necessitated by physical restrictions and with prior approval of the event race director and technical director. Bodywork • In accordance with regulations of national Federations or CIK-‐FIA. • CIK Homologated Plastic rear bumper is required. • CIK rule 2.5.3. Rear Wheel Protection: In all conditions, rear protection must at no time protrude beyond the external plane of the rear tires. • It is permissible to use a zip tie (1) or cable wire (1) to wrap loosely around the rear bumper bracket to the chassis from to prevent the rear bumper from falling off the chassis. The new style L-‐Shaped bracket is also an acceptable application. Only one of these items is acceptable. These items however will not exclude the driver from penalty if the bumper becomes detached or broken. • CIK rule 2.7.1.4: side pod protrusion rule outboard the quadrilateral formed by the four wheels is acceptable. • “Wet Conditions ”: Side bodywork may not be located outside the place passing through the outer edge of the rear tires. Side pod protrusion not allowed. • CIK rule 2.5.3: Rear Wheel Protection: In all conditions, the rear protection must at no time protrude beyond the external plane of the rear wheels. • Rear Protection – Side Body Work: o No modifications to chassis in regards to mounting of the rear tire protection system. o Minimum width of rear protection system under all conditions is 134 cm. o Bodywork and bumpers must conform to specification for current homologation period (CIK – 02, 08-‐11). o Side bumpers and side pods must match and front bumper and nose cone must match. o Modification of bodywork is limited to right side of radiator for clearance only. o Use of tape or other materials is allowed only for damage repair. o No alteration of the front or side bumper is permitted. In this instance, bumper is defined as “steel tubing elements”. 4. Tires: • At the US Open following tires only are allowed: o MG Yellow for Dry Race Tires o MG WT for Rain Race Tires •
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Strictly no modifications or tire treatment allowed. Marked direction of rotation must be adhered to for all tires. If tires are checked for modification we recommend Mini-‐RAE-‐Lite equipment. A threshold value of max 4ppm is recommended. No tire warmers, tires must be of ambient temperature upon presentation to the pre-‐grid/grid, and are subject to verification at that time. Karts with tires not of ambient temperature are subject to penalty. Upon verification of tire treatment, competitor is subject to immediate exclusion and additional penalty. Tires/Wheels: • Wheel diameter for all classes shall be five (5) inches. • Maximum overall width for all Junior and senior classes shall be: o Front – 135mm o Rear – 215mm 6.
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Data Acquisition: Systems, which permit the reading/recording of following data, only are allowed: o Lap time o Engine rpm (by induction on the high tension cable) o Two indications of temperature o The Speed of one wheel o Acceleration in X/Y US OPEN Spec Honda Technical Regulations (2015-‐V1.1) 4 www.MAXSpeedEntertainment.com o
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Direction position (via GPS position) Steering wheel angle sensor Connection of the data acquisition system to the original battery is allowed. During free practice also telemetry systems are allowed. Composite Materials: Composite materials (carbon fiber etc.) are banned except for the seat and the floor tray. Alloys from different metals/substances are not considered as composite materials (for example brake disks). Safety of Equipment: Helmets: o Effective as of January 1, 2015, all helmets must meet one of the following standards: Snell: K2005, K2010, M2005, M2010, M2015, SA2005, SA2010, SA2015, CMR-‐2007, CMS-‐2007, SFI: 24.1/2005, 24.1/2010, 31.1/2005, 31.1/2010, 41.1/2005, 41.1/2010. -‐British Standards Institution Specifications: Helmets with BSI A-‐type and A/FR-‐type BS6658-‐85 certification manufactured within the past 10 years are approved. o
Motocross-‐style bolt on chin and face protectors do not meet these standards. Helmet manufacturers recommend replacing helmets every five years. •
Helmet Support: o Are mandatory in Junior Classes, they must be unaltered. o The event organizer or track officials may require any class to use unaltered helmet supports. •
Suits: o
A full race suit, which covers the whole body, legs and arms. The driver suit must be manufactured for racing and constructed of heavy weight, abrasion resistant nylon or leather. We base this on WKA regulations and CIK Homologated level 1 or level 2 suits are recommended. 9.
Fuel/Oil: • Fuel: VP Fuel: C12 • Oil: Motul Kart Grand Prix • Official Fuel, as per event supplemental. • Competitor’s fuel will be verified by comparison with Digatron DT-‐15, DT-‐47, or DT-‐64. o Controlled Sample: § Competitor’s fuel must measure within +10/-‐5 points of control sample. § Technical inspection of fuel is not limited to Digatron test. 10. Legal Additions: •
Chain guard, engine mount, temperature gauge and tachometer/hour meter, inline fuel filter, catch can mounting brackets and supplemental ignition coil mounting brackets, within the limits specified in this document. o Non-‐tech items: Non-‐original fasteners, cir-‐clips, washers, throttle cable housing, zip-‐ties, fuel and pulse line (type and size), ground cable type and size, as well as length of coolant hoses are allowed unless otherwise specified, and catch bottle(s) and/or tank(s) are non-‐tech items. •
When taking any dimensional reading, of the following technical regulation, in the order of accuracy of 0,1 mm or even more precise, the temperature of the part must be between +10°C and +30°C. •
Before taking any decision based on this regulation a check for available Bulletins is mandatory: Bulletins can be found under www.maxspeedentertainment.com 11. Technical Specification: • Modification: o Neither the engine nor any of its ancillaries may be modified in any way. "Modified" defined as any change in form, content or function that represents a condition of difference from that originally US OPEN Spec Honda Technical Regulations (2015-‐V1.1) 5 www.MAXSpeedEntertainment.com o
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designed. This is to include the addition and/or omission of parts and/or material from the engine package assembly unless specifically allowed within these rules. The adjustment of elements specifically designed for that purpose shall not be classified as modifications, i.e. carburetor and exhaust valve adjustment screws. Genuine HONDA components only, that are specifically designed and supplied for the CR 125 (1997-‐2002) ANYTHING, WHICH IS NOT EXPRESSILY ALLOWED INTHE TECHNICAL REGULATIONS, IS FORBIDDEN. Any original equipment factory part may be used for comparison verification. Ambient temperatures: Fuel and tires must be at ambient temperatures when presented to the p re-‐
grid/grid during all official sessions. Engine: The 1999-‐2002 Honda CR125R. Parts from years listed in the Engine section above may be interchanged, except for items specified below. •
Cylinder Head: o The cylinder head will be checked using the Shockwave profile gauge tool. o The Cylinder Head must remain OEM with no modifications or machining (including polishing) of any kind. o Removal of mounting boss and modifications to the water outlets for the purpose of hose connection are allowed. o “Squish” or deck height measurement through the spark plug hole o For 1997-‐1999 cylinders: minimum of .050” o For 2000-‐2002 cylinders: minimum of is .045” § This check is a modest check to determine if any non-‐conforming modifications are present underneath the seal. § All squish measurements will be made using a .060” (nominal) solder parallel to the wristpin. If the measurement is found to be close to the minimum or below, the technical director will take squish reading from both sides of the squish area and an average of the two will be the official measurement. •
Cylinder: o Allowed Cylinders: 1997 to 2002 o No modification of the cylinder is allowed; such as, porting, polishing, machining ports, adding or deleting of ports, decking, or re-‐Nikasil. o Stock power valves may be removed and aftermarket plugs will be allowed, with no filling, welding, or modifying of the cylinder. Power valve plugs must be matched outside of the cylinder and re-‐
inserted. o The cylinder mounting flanges for retaining cylinder to cases may be spot faced in the area where the nut meets the flange only. o Some factory grinding, done prior to the Nikasil process, is present on many cylinders. o It is the Technical Directors right to, approve or disapprove any cylinder supplied by Honda and not modified. •
Cylinder Length: o 1997 -‐ 1999: (3.311” – 3.316”) o 2000 -‐ 2002: (3.307” – 3.312”) •
Piston assembly: o All piston related parts; such as, piston, piston ring, wrist pin bearing, and wrist pin must be unmodified stock OEM parts. o Wrist pin clips are non-‐tech. o No other aftermarket parts are permitted. o No modifications or treatments of any kind are permitted. •
Piston Ring: o
Minimum Thickness of the stock Honda Ring is .0375” US OPEN Spec Honda Technical Regulations (2015-‐V1.1) 6 www.MAXSpeedEntertainment.com §
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– (Plus (+) or minus (-‐) .002” will be allowed for lapping the bottom side of the ring Must be of magnetic material •
Crank, Rod, and Assembly: o Must remain OEM with no modifications allowed. o The two main bearings and seals are to be OEM. o The Flywheel key must remain set in place with no modifications to the keyway or key. o Only OEM parts are allowed for rod, bearing, washer, and pin replacement. Polishing to allow for slip fitting of crank is permitted. •
Transmission: o The use of Five (5) speeds as originally delivered in motorcycles or the use of six (6) speeds available through Honda in kit form is allowed. o The six speed transmissions must be 1994-‐96 OEM components. o All transmission components must remain OEM. No aftermarket parts are permitted. No polishing, grinding, or modifications of any kind are permitted. This also includes all bearings, seals, and shifting mechanisms. o Electric, air or pneumatic shifting mechanisms are not allowed; however, this may be waived with written permission of the race officials for special needs drivers. •
Clutch: o All related parts must remain OEM with no modifications of any kind. o The OEM number of plates must be installed with no deletion of plates. •
Engine Cases: o Internal modifications are not allowed and must remain OEM stock, including lapping and bearing pocket alignment. o External modifications may be allowed, with permission of the technical inspector. Allowed modifications will only pertain to non-‐performance modifications, such as machining the kick-‐starter boss and installing a plug in the kick start shaft hole. •
Exhaust: o The following exhausts are allowed. No modification of any kind is permitted. • RLV R4 (part # 6830) • R4 two piece (part #6820) • SKUSA SK-‐1 o All exhaust components are to remain intact during the race until released from scales or from technical inspection. o Exhaust flange is open, but must meet OEM length dimensions. No spacing can be used to adjust exhaust length, including flange, flange gaskets, or pipe spacers. o Exhaust silencer is open o At any point during competition, the race officials can request a competitor to change silencers if necessary for noise. o Junior shifter must run the (SKUSA S-‐5) exhaust restrictor mounted between the exhaust flange and cylinder. This item is subject to tech inspection at any point during competition. • Sound Emission: o A sound limit for all Spec Honda karts will be 92db and below. o Noise emission measuring procedure: The measuring place has to be at section of the track where the engine is operated under full load and at a rpm range of 12,000 to 14,000 rpm. The microphone has to be installed 1 meter above the level of the track in a rectangular angle to the track. The distance between the microphone and the kart on the ideal line on the track has to be 7.5 meters. The kart has to be operated under full load at the ideal line on the track •
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All CDI units must be 1999 OEM, with no modifications to internals or wiring. Race officials hold the right to require that a driver or drivers swap CDI units prior to entering the US OPEN Spec Honda Technical Regulations (2015-‐V1.1) 7 www.MAXSpeedEntertainment.com o
racing surface. If the driver does not comply, they may be disqualified from the event. This should take place before official timed practice •
Stator/Flywheel: o Must be OEM 1999 with no modifications, including wiring (except for repairs approved by the race officials). o Flywheel key must remain in place with no modifications. •
Stator: o The Blue anodized (SKUSA) timing Plate must be used. No modification to the hold down bolts or to the plate is permitted. No other modification to any of the ignition components that changes static timing is permitted; any attempt to exceed this adjustment amount is not permitted. Coil: o Must be 1999 OEM with no modifications. o It will be allowed to replace the lead and ground wires to facilitate mounting. o No ignition advance control can be performed with the coil. •
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Carburetor: o The approved carburetors are: • For all Spec Honda classes o Maximum Bore: Diameter of 38.6mm in an area .400” (10mm) wide measured inboard of the slide. This will be measured on the engine side of the slide. o Keihin 38mm PWK Sudco part # 16-‐153; o Keihin 38mm PWM Sudco part # 16-‐170. • Additional for junior shifter include: o Keihin 35mm PWK (Sudco, #016-‐150) o
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Note that the Sudco part numbers and website http://www.sudco.com/keihin.html are supplied for reference only. Pump around fuel systems are allowed. No additional components may be added to the carburetor. No internal or external modifications to the carburetor are allowed. •
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Air Box/Air Filter o Air boxes may have up to three inlet tubes. Each not to exceed 29mm +-‐ 1mm inside diameter and 95mm minimum length. o Junior shifter must use RLV air box with two 23mm inlet tubes, RLV part number 0300 red or 0301 black. Approved air boxes are limited to CIK approved and RLV Drivers may use an air box or air filter (unless regulated by track). If an air box is utilized, it must be in stock form with NO MODIFICATIONS to the box or the inlet tubes. Air box or air filter must remain installed and intact during all competition sessions until released from scales or technical inspection. § A dislodged air box or air filter may result in a disqualification or the driver may be removed from the racing surface A drain hole may be drilled in the bottom of the box, not exceeding 7mm diameter. Reed Cage, Manifold, and Reeds: o Only Stock unmodified, 1999 OEM CR125 Manifold (Honda Part Number 16221-‐KZ4-‐A10 – marked KZ4M) will be allowed. o Only Stick unmodified, 1999 CR125 Reed Cage (PN 14100-‐KZ4-‐J11). o For durability purposes, aftermarket replacement reeds will be allowed, including mono reeds or stiffeners; however, this only allows reed pedals to be installed without modification and does not permit multi-‐stage reeds. US OPEN Spec Honda Technical Regulations (2015-‐V1.1) 8 www.MAXSpeedEntertainment.com 11.2.
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Gaskets, Bearings, and Seals: o All bearings and seals must be OEM for the stated model years. o No modifications, including treatments, are permitted. o Gaskets must meet OEM specification, which includes thickness and number of gaskets used. o The use of common sealants on gaskets and the periphery of seals are permitted. Water Pump: o Water pump and housing must remain OEM. o No modifications to impeller or housing are allowed. o No axle driven or electric water pumps are allowed. Cooling Fluid: o Water only, products containing Glycol are NOT allowed. o Water Wetter solutions and anti-‐corrosion solutions are allowable in cooling system. Fuel Pumps: o A single, (pulse-‐type driven) fuel system is allowed. o Any single additional pumps must be for used for pump around system. o No electric fuel pumps allowed. Radiators: o Primary radiator must be mounted to the left or the right of the Driver. o Supplemental radiators may be mounted to the left or the right of the driver. o They must be mounted above the chassis frame. Maximum height is 50cm from the ground (excluding cap and fitting). o The event officials have the right to inspect all mounting hardware and position, and may request a driver to change all. Spark Plug: o Must be stock, unmodified commercially available spark plugs. May be compared to a known stock plug to determine any modification. Must have washer or CHT lead in place. o The spark plug may not protrude below the last thread of the Cylinder Head (Spark Plug Protrusion). o Over all length of a spark plug thread may not be longer than 18.5 mm. MSE has the right to inspect any engine or any part at any time. After inspection, the engine may be resealed by a technical official. • Refusal to submit to inspection will result in disqualification. 12. Scoring Transponder: o Transponder may not be located forward of the tangent point defined by the radius transitioning to side of the seat and seat back. Every effort should be made not to mount the transponder directly above any solid material between transponder and track surface. 13. Cameras: o Cameras may or may not be allowed during official sessions, as per the event regulation supplemental. o Cameras mounted on chassis, will not be permitted without prior written permission of Race Director. o Mounting Procedures – Only after use of cameras has been allowed, mounting procedures must be followed. Only one (1) camera per kart is permitted; all camera mounting shall be subject to Inspection and shall be subject to removal by technical personnel at any time during event. o “Go-‐Pro” type cameras, only approved mounting location is on front number panel directly below numbers, and be fixed in a horizontal forward facing position. o “Smarty Cam Mounting” or similar type may be mounted on welded main frame rail seat strut only. Camera mounted in this position must be level or below highest portion of seat. Only mounting hardware supplied with “Smarty Cam” are permitted. Camera must be facing forward. o All cameras should have a tether retention system. o Cameras may never be mounted on driver’s helmet or driver’s person. o Violation may result in position penalty and or fines. 14. Ballast: o Individual Weights equal to or greater than 7 pounds: minimum 2 bolts, of minimum 6mm diameter/double nylock or metal lock nuts or single nut drilled and keyed. •
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Individual Weights less than 7 pounds: minimum 1 bolt, of minimum 8mm diameter/double nylock or metal lock nuts or single nut drilled and keyed. Stacked Weights: minimum 2 bolts, of minimum 6mm diameter/double nylock or metal lock nuts or single nut drilled and keyed. 15. Chain Guards: o The guard must be constructed of metal or plastic material, and securely mounted, so as to not fall out of line with the chain. o The guard must extend around the axle drive sprocket to at least below the centerline of the sprocket, and must cover the chain as viewed from directly above. Loosely mounted, flimsy guards tied to the chassis will not be accepted. o It is highly encouraged to use full coverage clutch/chain guard coverage such as, OTK, KG, Tillet or similar chain clutch guard US OPEN Spec Honda Technical Regulations (2015-‐V1.1) 10