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2009 MX Zx 600 RS Key Features and Improvements

2009 MX Zx 600 RS Key Features and Improvements. Powertrain Rotax® 600RS engine NEW dual air intake system NEW tuned pipe support Runs on 98E octane fuel. 2009 MX Zx 600 RS Key Features and Improvements. Suspension – NEW Calibration Front and Rear SC-5 rear suspension

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2009 MX Zx 600 RS Key Features and Improvements

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  1. 2009 MX Zx 600 RSKey Features and Improvements • Powertrain • Rotax® 600RS engine • NEW dual air intake system • NEW tuned pipe support • Runs on 98E octane fuel

  2. 2009 MX Zx 600 RSKey Features and Improvements • Suspension – NEW Calibration Front and Rear • SC-5 rear suspension • NEW rear arm geometry and shock linkage • NEW, STRONGER rail design: better cornering and braking • NEW stronger coupling system on slide rail • 4 rear idler wheels

  3. 2009 MX Zx 600 RSKey Features and Improvements • Suspension – NEW Calibration Front and Rear • Dual A-arm front suspension – NEW geometry for sharper cornering • Wider ski stance • NEW steering ratio • NEW ski spindle • NEW A-arms • Adjustable width, adjustable caster • ALL-NEW C-40 Racing Clicker shocks • 16mm shock shafts • Piggyback design on all four shocks for better oil flow, higher capacity • External high/low speed compression adjustments • External Rebound adjustability on front shocks

  4. 2009 MX Zx 600 RSKey Features and Improvements • Chassis • NEW Reinforced castings throughout • NEW Stronger engine supports • NEW Wider, stronger running boards • NEW rolled edge extrusion • NEW integrated footrest • NEW toe hold • NEW seat shape and height for easier transitioning • Exhaust deflector • 20L fuel tank standard; 40L available for cross-country racing • Multi-function gauge package with EGT record mode

  5. 2009 MX Zx 600 RSKey Features and Improvements • Driveline • NEW track; designed for improved durability, better cornering and holeshots • NEW Brembo‡ brake caliper: stronger casting and better resistance to heat transfer through piston • NEW primary and secondary clutch calibrations: stronger holeshots • TEAM‡ roller secondary: floating design on jackshaft • BRP-design slip gear: better snap ring retention • Stronger drive axle: better welding process • Stronger jackshaft: better welding process

  6. 600 RS Engine • New ECU Mapping • New Dual Air Intake System • New Tuned Pipe Support • New stronger motor mounts • Runs on 98E octane fuel

  7. 600 RS Engine • We recommend using a good quality 98E octane fuel • Peak Torque @ 8100 RPM • Peak HP @ 8300 which builds to 8500 with hot pipe

  8. 600 RS Engine • Technical Data • Piston to cylinder clearance • -.004 + or -.0005 • Piston Ring end gap • -min. .016-.021 • -max. .028-.033 • Replace base gasket with exact size only, same as original

  9. 600 RS Engine Pipe Heat Function • On dash display, select EGT • Depress holeshot button, slowly depress throttle, build to approx 5000 RPM, avoid backfire from too much throttle

  10. 2009 600RS Engine • Power & EGT vs time MY2008-2009

  11. 2009 Rev-XP 600RSCarburetor Synchronization&TPS adjustment procedure Ref pg 47

  12. Tools Required • 10mm open end wrench • Phillips Screwdriver • Small mirror • Small Flashlight • Supply Harness – Part # 529035869 (7-19) • 12v Cable Supply – Part # 529035997 (7-20) • 12 volt battery

  13. Carburetor Synchronization • Remove the airbox. • Place a mirror so you can see both carb slides. • Check the throttle cable tension at the throttle lever (slack should be at a minimum). • Press the throttle lever to WOT. • Look at the carb slides to see if they are equal in height and clear the bore of the carbs. Adjust the throttle cables if they do not. • Check the throttle cable tension again at idle position (minimum slack). • Slowly open the throttle and watch to see if both carb slides rise at the same time.

  14. Carburetor Synchronization • Adjust the idle screw so both carb slides open at the same time. • Again, check the throttle cable slack at the idle position. Must be minimum slack in the cable. • Tighten the cable jam nuts and recheck the carb slide operation. • Re-install the airbox. • Your carb slides are now synchronized

  15. TPS Adjustment • Using the electrical supply harnesses and the 12v battery, connect to the diagnostic port on the vehicle. • The instrument cluster will light up. • After the “wake-up” of the dashboard, push and hold the throttle lever to W.O.T. position. • Press on the “Holeshot” button, hold it for 5 sec.

  16. TPS Adjustment The check engine light will appear when the TPS adjustment is complete. Release the throttle lever and the “Holeshot” button. Disconnect the battery and the supply harness. Put back the diagnostic port in its connector on the vehicle.

  17. TPS location, diagnostic connector, harness and battery TPS Battery Diagnostic connector Harness

  18. Clutching Understanding basics, crucial for tuning • Driver input-Data acquisition very important • Know and tune to peak TORQUE RPM and peak HP RPM • Testing - learn what changes to make for track, conditions, temperature, elevation, air density • Knowledge of these factors and cumulative efforts on your part will make the winning difference

  19. Clutching Tools Needed • Drive clutch puller # 529 022 400 • Button retainer forks # 529 005 500 • Drive pulley retainer # 529 035 674 • Spring compressor # 930001

  20. 600 RS Tuning Components Lightweight TRA III Drive Clutch • TRAIII Adjustments • Drive Spring • Ramp • Pin Weight • Calibration Screw( Clickers) Team Performance LW Driven clutch • Team Performance Adjustments • Driven Spring • Helix • Belt Deflection

  21. Drive Spring Controls Engagement RPM well as shift RPM • TRA springs measured @74mm (2.9 in.)-41mm (1.6 in) Read with stripes down • Large assort of springs available

  22. TRA Drive Springs Ref pg 139

  23. TRA Drive Spring

  24. TRA Drive Spring

  25. Ramp • The profile of the ramp controls the axial or shift force generated to the drive belt • It is the angle of the ramp at the point of roller contact that determines the shift force • BRP has a wide variety of ramp profiles available

  26. Ramp Characteristics Ref pg 129

  27. Ramp Force vs Position

  28. TRA Ramp Graph

  29. Roller Pin Weight • Shift force directly controlled with weight of pin • Lighter pin weight-Higher RPM • Slower upshift • Heavier pin weight-Lower RPM • Faster upshift

  30. Ref pg 122

  31. Pin Weight Graph

  32. Calibration Screws(Clickers) • BRP only manufacture to offer quick external shift RPM adjustment • Cam adjuster allows you to raise or lower ramp, changing profile • Clicking up to higher # will slow upshift and raise RPM • Clicking down to a lower # will upshift faster and lower RPM

  33. Ramp Rotation Chart Ramp Force-LBS #1 1370 #2 1355 #3 1315 #4 1275 #5 1240 #6 1225 Rotation Measurement 1-2 .698 deg .014 2-3 1.062 deg .031 3-4 1.245 deg .032 4-5 1.225 deg .027 5-6 .540 deg .018 Total 4.770 deg .122

  34. Team LW Driven Clutch

  35. Driven Spring • Stiffer Spring-Slower upshift-Faster Backshift • Softer Spring-Faster upshift-Slower Backshift • Spring measured @2.2-1.1 in.

  36. Team Driven Springs Ref pg 169

  37. Team Helixes Ref pg 164

  38. Helix Graph

  39. Team Helixes Ref pg 168

  40. Floating Driven 3mm End Play Add 1-1mm shim 2mm Total End Play

  41. Pulley Alignment and Distance Ref pg 187

  42. BRP Slip Gear Removal Part # 529 036 122

  43. XP Gear Ratio-MPH Ref pg 197

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