22nd February 2011
Radical Performance Engines Technical Bulletin Archive
In an effort to continually improve our communication with customers, every year we distribute our
technical bulletin archive.
This is to bring new teams / race team members up to speed with bulletins / upgrades which have
been carried out historically.
Please take the time to read this document and if you have any questions relating to the
documents, contact our technical department on the details below detailing the bulletin title and
date for our reference.
E-mail: technical1@radicalperformanceengines.com
Phone: 00 44 (0) 1733 331919
Mobile: 00 44 7795 490850
Company Name Change
Powertec Engineering changed its company name to Radical Performance Engines in January
2011.
As a result, the companies e-mail addresses changed from @powertecengineering.com to
@radicalperofrmanceengines.com. Please see the last page of this document for an up-to-date
contacts list.
Bulletin Amendments
Bulletin Date: 09/05/2010
Bulletin Title: Powertec Extended engine warranty for Powertec Standard 1300, 1340 and 2.6V8.
RPX 2.7 and RPX 2.7H V8’s are covered by a 40 hour limited warranty.
Bulletin Date: 27/07/2010
Bulletin Title: Fitting of V8 Oil Filters
RPE RP-Series V8 Oil Filter fitting/tightening procedure
The procedure for tightening the oil filter is:
1) Apply a thin layer of engine oil to the oil filter O-Ring.
2) Wind the filter on, until the O-ring touches its mating face on the engine casing.
3) Then turn the filter though 360°.
The oil filter is now tight enough, and the next step is to apply the jubilee clip and lock-wire as
outlined in the bulletin entitled ‘Fitting of V8 Oil Filters’ on page 8 of this document.
Date: July 2009
To: All Radical Distributors and Owner of SR300421 to SR300459 and PR600029 to PR600037
Subject: ACT1 Upgrade
Dear Radical Owner/Radical Distributor
It has become apparent that an essential software upgrade must be carried out to all Radical
Sportscars running Life Racing ECU's. Our records show that you have a vehicle(s) requiring
upgrade. Distributors please forward this email to the owner of the car if it is not maintained by you.
The models that are affected by this recall are, Radical SR3 chassis number SR300421 through to
SR300459 and PR6 chassis number PR0600029 through to PR0600037.
It is essential that the Life ECU(s) are sent to Powertec immediately for the upgrade to be carried
out, failure to do this may result in the engine failing. If you do not have the upgrade carried out
your engine warranty will be null and void.
If you have to use the vehicle in the meantime it is essential that you run the car on high octane
fuel with a minimum of 98 RON octane rating until you can return the ECU to Powertec. It is also
worth reiterating that all engines should be run on a minimum of 98 RON octane fuel at all times.
You will be contacted by phone to discuss this upgrade, so that we can confirm that you have
received this email to keep our records up to date could you please respond confirming that you
have read and understood the content.
If you are returning ECU(s) by post please forward it to me at the address below, with a record of
the chassis number of the car it was removed from. We will use this information to keep our
records updated.
ECU’s will be updated and returned immediately.
Alistair Perry
Powertec Engineering Ltd
24 Ivatt Way
Westwood
Peterborough
Cambridgeshire
PE3 7PG
United Kingdom
Many thanks in advance for your assistance with this matter.
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Date: July 2009
To: All Radical Distributors and Owners of Powertec Suzuki K8 Titanium-Valve Engines
Subject: Powertec Suzuki K8 Titanium Valve Engines
We have noted on engines and ECU’s being returned for re-build, that there is a dramatic
increase in the incidents of engines being driven on the rev limiter before up-changing
gears. This can be worse on cars used as demo or school vehicles.
The high frequency resonance caused by this practice can damage the lightweight valve train
components in this engine.
Warning: This can invalidate any engine warranty
Immediately: we need the data from your ECU to advise you the best course of action,
please send this data to technical1@powertecengineering.com along with the chassis
number(s) of the vehicle(s) that you have taken the data from.
Please take this communication as reasonable advice and warning of impending problems and
costs to you if you are driving or allowing your cars to be driven in this way.
So that we can confirm that you have received this email to keep our records up to date could you
please respond confirming that you have read and understood the content.
2
Date: October 2009
To: Radical Distributors
Subject: K8 Drive Couplings
TECHNICAL BULLETIN - K8 COUPLING
PLEASE NOTE THIS ONLY APPLIES TO THE RADICAL SR3’S FITTED WITH A K8 ENGINE
Dear Radical distributor,
It has recently been brought to our attention that there have been incidences of the coupling stop
bolt coming loose. To prevent further occurrences of this we have changed our coupling and stop
bolt fitting procedure. We have also done away with a shimming washer, we now have a new style
stop bolt washer and a longer stop bolt.
We have provided you with a kit to carry out the re-installation of K8 couplings, which is currently
on its way to you. We strongly recommend you carry this out to all your SR3’s running K8 engines
with immediate effect.
Kit contents
-Coupling Holding Tool
-Loctite 648
-Loctite 7240 activator
-36mm socket
-New 25mm countersunk m8 stop bolts
-New stop bolt washer
-Drive unit removal instructions
-Coupling and stop bolt fitting instructions
If you have any questions please don’t hesitate to contact Powertec on the details below.
Please reply to this e-mail to confirm you have read and understood it.
Technical
Powertec Engineering Ltd
technical1@powertecengineering.com
M: +44 7795 490850
T: +44 1733 331919
F: +44 1733 333666
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Date: 09/02/2010 and Re-Issued 21/05/2010
To: Radical Distributors and Owners of Powertec Standard 1300, 1340 and 2.6 V8 Engines
Subject: - Powertec Extended engine warranty for Powertec Standard 1300, 1340 and 2.6 V8.
Dear Radical Customer,
Due to the constant improvement programme Powertec undertakes, reliability of our engines is
constantly improving. We can now offer all Radical Sportscars customers who have a 1340cc, RPA
2.6 V8 or a standard 1300cc Powertec engine, an extended engine warranty.
The new warranty will cover the engine for 40 hours running time, instead of 30.

All new 1340cc, RPA 2.6 V8 and standard 1300cc engines purchased from Radical or
Powertec since 1st January 2010 will be covered for 40 hours.

All other 1340cc, RPA 2.6 V8 and standard 1300cc engines will be covered for 40 hours
after their next rebuild, providing all recommended upgrades are carried out.
If you are unsure about the specification of your engine, please feel free to contact us with your
engine number so that we can resolve any concerns you may have.
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Date: 21/05/2010
To: Radical Distributors and Radical Customers
Subject: Engine Booking in sheet
To continually improve our customer service Powertec have now introduced a new engine booking
in sheet. This sheet must be completed and returned to Powertec before any work will commence
on your engine. This sheet can be submitted by E-mail, fax or by hand using the following contact
details:
service@powertecengineering.com
Tel: 01733 331919
Fax: 01733 333666
If you have any questions or require any further information about this then please do not hesitate
to contact Daniel Phillips using the above details.
The start date for use of this form is 24.05.10.
Your cooperation in this matter is greatly appreciated.
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Engine Booking in Sheet
Distributor
Customer
Contact No
Payment Method
Date
Team
Email Address
VAT Reg (If applicable)
Event
Invoice Address
Delivery Address
Information on Car/Engine
Chassis No
Hours on ECU
Model:
ECU No/Type
*The engine ECU must be returned with the engine*
Comments on Engine/Work Required
Date engine required back by:
Courier Used:
Container Used:
Metal
Engine No:
Oil System:
Quote required before build?
Comments on Engine:
Wooden
To use on return:
Pallet
Seal No:
Engine Type:
Yes
Other:
No
With Engine
Not With Engine
ECU
Starter
Alternator
Spark Plugs
Gearbox Coupling/Sprocket
Gear Lever
Exhaust Gaskets
Coil Mounting Studs
Clutch Push Rod
Slave Cylinder
Paddleshift Bracket
Head Drain Pipe
Throttle Bodies/Carbs
Coils & Leads
Primary Exhaust Pipes
Engine Stand
Airbox
Loom
Fuel Pump
Fuel Filter
Pressure Regulator
Additional Parts sent in:
FOR OFFICE USE ONLY
Date of arrival:
Data Downloaded By:
ECU Engine Report Completed By:
Additional Information Location:
Job Card Raised:
Box Location:
Location on PC:
Report No:
Y/N
P://liferacing/trackmapsanddata/data/2010/
Job No:
*No work will commence on your engine until a completed copy of this sheet is received by Powertec*
PTJW19052010
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Date: 21/05/2010
To: Radical Distributors and Radical Customers
Subject: Oil pressure Trip
The following applies to SR3, SR4, SR8 and PR6 cars running a Life Racing ECU.
Powertec have introduced a trip in the ECU’s calibration, which shuts the engine down if the
engine’s oil pressure drops to a dangerously low level.
This has been introduced, due to instances where cars have continued to be driven with very low
oil pressure, even with the low oil pressure light on.
The engine will stop if the oil pressure is below its threshold for one second. This could cause
some engines to cut out unnecessary, unless teams pay particular attention:
 When looking through engine data. (Oil surge (Low oil level) or faulty oil pressure
sensor could cause the engine trip to stop the engine)
This is not a guaranteed device to stop all issues, the onus is still on the driver to observe warning
lights and the ‘sound and feel’ of the engine.
The benefits of having the trip enabled in the ECU are as follows:

If an engine suffers oil surge to the extent where damage could be caused, the trip will stop
the engine. This does not mean that no damage could be caused by oil surge. It does mean
that if the trip is enabled, the amount of damage is greatly reduced.

Less damage caused to engine components, should the engine loose oil pressure, through
another reason.
If the oil pressure trip does cut the engine out you must contact Powertec immediately. If you are at
a Radical race meeting contact a Powertec technician. If not, please use the contact details below.
Technical
Radical Performance Engines
E-mail: technical1@radicalperformanceengines.com
M: +44 7795490850
T: +44 1733 331919
F: +44 1733 333666
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Date: 28/09/10
To: All Powertec V8 Owners and Teams
Subject: Fitting of V8 Oil Filters
Bulletin No 063 Fitting of Oil Filter on a V8 27/07/2010
RE ISSUED 28/09/2010
Dear Powertec RP Series V8 Owner/Team,
Please be aware that when fitting an oil filter on a V8 it must have a jubilee clip fitted around it. This
jubilee clip must then be lock wired to the bolt on the crank cases as the pictures below show.
WARNING - THE OIL FILTER COULD COME LOOSE RESULTING IN A LOSS OF OIL
PRESSURE AND SUBSEQUENT ENGINE DAMAGE IF THE ABOVE IS NOT DONE
CORRECTLY!
Please see pictures below for correct fitting of jubilee clip and lockwire.
The picture shows that the lock wire is fed through the bolt head and twisted. It is then fed down
one side of the screw in the jubilee clip, around and back up the other side. It is then twisted to lock
it off.
All V8 engines, both new and rebuilt leave the Powertec workshop in this manner.
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Date: 16th November 2010
To: Radical Distributors and Owners
Subject: Radical SR8/Powertec RP Series V8 data base update
Dear Radical Distributor/Owner
Due to our continuous efforts to improve our communication with our customer base and keep you
informed of vital technical information we are carrying out an update of our Radical SR8/Powertec V8
owner database.
Our reason for contacting you is our records indicate that you fall in to the above category.
If I could just ask that you spend a few minutes of your time completing the following questions that would
be very much appreciated.




The chassis and engine number of the vehicle you own/run on behalf of the owner? (if you are a race
team please detail all vehicles you run on behalf of their owners)
If you have sold the vehicle and you have the contact details for the new owner please forward them to
us (an email address would be the preferable form of contact)
Is the vehicle currently being used and what championships/events do you intend to use the vehicle
for?
The number of hours the engine has run for?
IMPORTANT NOTE TO ALL CUSTOMERS
Please be aware, our records indicate that, your engine may not be covered under the Powertec Limited
Warranty as it may not have been rebuilt by Powertec Engineering within the last 12 months, therefore it
may no longer be covered by our terms as indicated in the Limited Warranty document
“No more than 30 hours of running time or 12 months, whichever is the sooner, may elapse before the
engine is stripped and rebuilt by Powertec “
It is important that you contact Powertec at your earliest convenience to confirm the current status of your
engine and to discuss a refresh/upgrade of your engine to reinstate your warranty cover if necessary.
With best regards
Daniel Phillips
Sales and Customer Liaison
Powertec Engineering Ltd
Service@powertecengineering.com
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Date: 19th November 2010
To: Radical Distributors and UK Based Race Teams
Subject: 2008 model onward (K8/9/10) cam drive chain inspection
Models affected: Powertec GSX-R1300R models 1340 and 1500
Serial numbers: 1340cc 1340-059 onward / X704-116108 onward
1500cc 1500-131 onward / X704-122149 onward
Dear Radical Distributor
As most of you are aware, this year we have seen numbers of cam drive chains failing in
the above mentioned models, in order to prevent further costly failures it is important that
you regularly inspect your engines cam chain whilst we improve components to overcome
this issue.
Using this method of preventative maintenance we have identified a number of chains
before they have failed
We are utilising some of the world’s top engine designers and engine component
manufacturers to address this matter.
Please find instructions regarding the inspection and maintenance of the GSX-R1300R
cam drive chain, on pages 11 to 14 of this document.
As a minimum the cam drive chain should be inspected after every day of use (ideally after
each session on track) the condition should be reported to Powertec if necessary for
further instruction.
We kindly request that you forward this information to your customer base and confirm
receipt of this email by responding to the addressee
If we can be of further assistance please do not hesitate in contacting our Technical
Department using the contact details on page 14 of this document.
Regards
Technical
Powertec Engineering Ltd
technical1@powertecengineering.com
M: +44 7795 490850
T: +44 1733 331919
F: +44 1733 333666
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K8 1500cc Cam Chain Check Instructions
1. Remove the coil pack, cam cover plate and all four spark plug leads. Remember the
position of the leads, as it is critical they go back in the same position. To remove the coil
bracket, cut the cable ties and remove the two 5mm cap head bolts, shown in the picture
below. To remove the cam cover plate, remove the four 5mm bolts, shown in the picture.
Cable ties
Coil Pack
Coil Pack Bracket
5mm Bolts
5mm Bolts
Cam Cover Plate
HT Leads
2. Unplug the cam sensor.
Cam Sensor
Unplug here
3. Remove cam cover by removing all 6 mounting bolts (Please see picture below).
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4. Remove the cam cover gasket from the cylinder head. Be careful not to damage the gasket
when removing it.
5. Once the cover is removed, indentify which type of cam chain you have, either a multi link
or a roller type. Both types of chain are shown in the pictures below.
Multi-plate Chain
Roller Chain
6. If a roller type chain is fitted, look on the top edge of the chain for ‘polishing’. The pictures
below show a chain which has polishing on the edge and one which doesn’t.
Polished Roller Chain
New Roller Chain
7. If chain is found to be polished – contact Powertec on the details on page 14. If the chain is
not polished on the top edge, please ignore points 8, 9 and 10.
8. If you have a multi link chain you will need to remove the top cam chain guide, this is done
by removing the two 5mm cap head bolts (Please see pictures below).
Top cam chain guide
Two 5mm cap head bolts
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9. Turn the guide over to inspect for wear, if you see any wear or scoring – contact Powertec.
See pictures of a normal guide compared to a scored guide.
Normal Guide
Scored Guide
10. The scoring is caused by a broken link in the chain (Please see picture below).
11. If the guide is found to be ok, it can be re-fitted. Make sure the guide is clean, and the re-fit
procedure is the reversal of removal. The two cap head bolts require a small amount of
thread lock. (Loctite #243 and are torqued to 90lbin or 7 ft/lbs).
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12. Clean areas of the head where silicon is required to aid the seal between the head and cam
cover gasket. These areas are indicated by the red lines on the photos below.
It is important that these areas are clean and oil free. Once these areas are clean, apply some
new silicon.
The gasket will leak oil from these areas if the above procedure is not done correctly.
Fit the gasket to the cam cover first, then place the cam cover and gasket together onto the
head, ensuring the gasket is seated nicely and is not trapped anywhere. The torque setting for
the six cam cover bolts is 10 ft/lbs.
13. Re-fit the coil pack, spark plug leads cam cover plate and re-connect the cam sensor.
14. Carefully check for leaks when car is first ran on track.
If you have any problems with any of the above, please contact Powertec on the details below.
E-mail – technical1@powertecengineering.com
Phone - +44 (0)1733 331919
Technical phone - +44 (0) 7795490850
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Date: 10th December 2010
To: All Radical Distributors
Subject: Powertec GSX-R Engine Oil Systems – Issue 003
Dear Radical Distributor,
We have recently seen evidence that engines are not being installed in the correct
manner.
Please find a technical bulletin, explaining the different types of oil systems now in
circulation, on pages 16 to 20 of this document.
Please take time to read it, as we have added some additional diagrams since we last sent
it out.
Please reply to service@powertecengineering.com to confirm that you have read and
understood the attached information.
If you have any questions, please feel free to contact us on the details below.
Regards,
Daniel Phillips
Sales and Customer Liaison
Powertec Engineering
service@powertecengineering.com
Tel: +44 (0) 1733 331919
15
Types of Oil Systems
Due to a number of different oil cooling systems now in circulation the oiling
system must be confirmed before the engine is fitted.
Oil Type Number 1 - Blanking Plates, No Jet
This type of oil system can be used with both Powertec cast (Silver) and billet
(Gold) dry sump pans! If the engine is fitted with a cast sump pan, there will
be no blanking plate on the sump pan, just one on the engine.
Oil System Number 1: 2 blanking plates on the OEM oil cooler in and outlet
ports and the oil jet behind the oil filter is removed.
Oil System Number 2: -8 or -10 fittings on the engine’s OEM oil cooler in and
outlet ports, and the oil jet behind the oil filter has a 3mm hole drilled in it.
Oil System Number 3: -8 or -10 fittings on the engine’s OEM oil cooler in and
outlet ports and a bung behind the oil filter, in place of the oil jet.

On later model engines which are fitted with a cast type sump pan,
there is only one type of oil system regardless of what type of car the
engine is fitted into. One blanking plate on the oil cooler inlet port
and the oil jet behind the oil filter is removed.

If you are unsure as to the specification of your previous engine
Powertec can provide you with the necessary information.

A Powertec technician can also confirm the specification for you if the
exchange is to take place at a race meeting.

If in any doubt please Phone or Email
Tel
+44 (0)1733 331919
Blanking plates are fitted to the engine’s OEM oil cooler in and outlet ports.
The restrictor jet behind the oil filter is also removed. The oil return pipe
from the scavenge pump goes through the oil cooler (or water to oil heat
exchanger) before returning to the oil tank.
Email
info@powertecengineering.com or
IMPORTANT
technical1@powertecengineering.com
When this oiling system is used, the jet behind the filter must be removed.
IF THIS IS NOT DONE IT WILL RESULT IN ENGINE FAILURE.
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Oil System Number 2 - Oil Cooler Fittings and Jet
This system can only be used with Powertec billet dry sump pans!
There are two fittings on the engine’s OEM oil cooler in and outlet ports,
they are either -8 or -10. In this case there is a restrictor jet with a 3mm hole
in it, behind the oil filter. The oil return from the scavenge pump goes
directly back to the oil tank.
Oil System 3 – Oil Cooler Fittings and Bung
This system is mainly used on the Radical SR4, as it has long hoses to and
from the oil cooler.
There are two fittings on the engine’s OEM oil cooler in and outlet ports,
they are either -8 or -10. In this case there is a bung behind the oil filter. The
oil return from the scavenge pump goes directly back to the oil tank.
IMPORTANT
IMPORTANT
When using this oiling system, the jet behind the filter must have a hole
drilled in it.
When using this oiling system, the jet behind the filter has no hole drilled, it’s
a solid bung.
IF THIS IS NOT DONE IT CAN RESULT IN ENGINE FAILURE.
IF THIS IS NOT DONE IT CAN RESULT IN ENGINE FAILURE.
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To dry sump tank
Oil System 1 – Cast Sump Pan
This is for a Powertec Hayabusa engine with a cast sump pan.
Breather Pot Connection
FROM UNION ON TOP OF
ENGINES BREATHER POT
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Oil System 1 – Billet Sump Pan
To dry sump tank
Breather Pot Connections
This is for a Powertec Hayabusa engine with a billet sump pan.
FROM UNION ON TOP OF
ENGINES BREATHER POT
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To engine breather tank
Oil System 2 & 3
FROM ENGINES
BREATHER POT
To dry sump tank
Breather Pot Connections
20
Date: 07/01/2011
To: Radical Distributors
Subject: NEW YEAR, NEW NAME: POWERTEC ENGINEERING BECOMES RADICAL
PERFORMANCE ENGINES
Dear Radical Distributor,
Powertec Engineering enters 2011 with news of an
extensive rebranding and business overhaul,
changes of benefit to both its customers and
suppliers. Radical Performance Engines (RPE) is
the new name for Powertec, demonstrating the
business' growing ties with parent company Radical
Motorsport Ltd.
The name change coincides with a number of behind-the-scenes changes, that increase the
development, communication and quality control ties between engine and chassis/powertrain staff
even further, within the Radical group. Customers can expect even better service, RPE recruiting
three additional staff in recent weeks in response to the growth of the business.
Another important step forward is in the redevelopment of RPE's website.
www.radicalperformanceengines.com offers visitors a greater wealth of information on the current
range of engines, transmissions and tuning products, with buyers directed to a new, more intuitive
and comprehensive online shop. This new online portal also has many synergies with upcoming
improvements in Radical Sportscars’ own website; check back soon at www.radicalsportscars.com
to find out more.
Radical Performance Engines new website
www.radicalperformanceengines.com
Radical Performance Engines online shop
www.rpeonline.co.uk
Oil System 1 – Cast Sump Pan
21
Date: 07/01/2011
To: Radical Distributors
Subject: Engine Cut Off’s: Low Fuel Pressure and High Coolant Temperature
Dear Radical Distributor,
As we are constantly striving to improve engine reliability and performance, we have added two
more ‘cut off’s’ in to the ECU calibrations.
As you know, last year we added the ‘Oil Pressure Cut Off’ which stops the engine running, should
the oil pressure drop to a level where the engine may suffer damage.
We have now added the following to our latest calibrations.
Low Fuel Pressure Cut Off
The ECU will switch the engine ‘off’ should the fuel pressure drop to 2.2bar or below for more than
5 seconds.
Coolant Temperature Cut Off
The ECU will switch the engine ‘off’ should the coolant temperature exceed 120°C for more than 5
seconds.
It can be determined in the engine data whether your engine stopped due to an engine cut off.
Should your engine ‘cut off’ you must contact Radical Performance Engines technical department
on +44 (0)7795 490850 or technical1@radicalperformanceengines.com.
If you are unable to get in contact with RPE, the engine will re-start after the master switch has
been turned off and on again. Ensure that you find and repair the cause of the engine cut off before
attempting to run the car on track for any length of time.
These new settings have been added into cars built after 01/01/2011.
Retrospectively the fuel and coolant temperature trips can only be added in to the ECU’s
programmed with the latest internal software.
Cars that would accept this software update are the following:
SR8 00106 onwards
SR3 00544 onwards
PR6 00044 onwards
SR4 00079 onwards
All customers with one of the above mentioned cars, will automatically be upgraded to these latest
trips in their ECU calibration at their next engine re-build.
Please ensure that your ECU is always sent along with your engine.
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If you would like to receive the updated trip calibration before your next engine refresh, please
contact Daniel Phillips on +44 (0)1733 331919 or service@radicalperformanceengines.com to
discuss this.
Daniel Phillips
Service and Customer Liaison
Radical Performance Engines
E: service@radicalperformanceengines.com
T: +44 (0)1733 331919
F: +44 (0)1733 333666
23
Date: 04 February 2011
To: Radical Distributors
Subject: Radical Performance Engines Contact Details Update
Dear Radical Distributor,
In an effort to continually improve our service and response times to customers we thought it worth while
sending you an updated contacts list.
This should ensure your enquiry is responded to accurately and in a timely manner.
If we can be of any further assistance, please do not hesitate in contacting the relevant member of staff on
the details below.
Ted Hurrell - Technical Director
Tel: +44 1733 331919 E-mail: ted@radicalperformanceengines.com
James Williams - Manager
Tel: +44 7795 498102 E-mail: jamesw@radicalperformanceengines.com
Paul Barker - Technical
Tel: +44 7795 490850 E-mail: technical1@radicalperformanceengines.com
Rich Webb – Dyno Technician
Tel: +44 1733 331919 E-mail: workshop@radicalperformanceengines.com
Daniel Phillips – Sales and Service
Tel: +44 1733 331919 E-mail: service@radicalperformanceengines.com
Lee Deane - Parts and Purchasing Manager
Tel: +44 1733 331919 E-mail: parts@radicalperformanceengines.com
Alistair Perry – Website and Media
Tel: +44 1733 331919 E-mail: alistairp@radicalperformanceengines.com
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