Cycle News - Archive Issues - 2000's

Inside Max Biaggi's Yamaha YZR500 sure can be monitored inside the cylinder. After every session, the Quickshifter Engine management Bodywork heads on Biaggi's bike are removed to check the pistons and cylinders for Biaggi aside, a tiny black box under The in the You could be the proud owner of a any sign of damage caused by debris the rev counter is one of the most gearshifter which tells the engine- new R 1 for the same price as the from the track or detonation, which important features on his YZR and management system what gear Biag- bodywork of a YZR. A full set, made can occur when a portion of the provides key information that could fuel/air mix begins to burn sponta- be the difference between success gi is in and how much pressure his left foot is putting on the lever. Engi- from the lightest carbon fiber, includes a fairing, seat, tank, front neously after normal ignition has finished. Crust explained: "We can see and failure. The programmable engine-management system offers a neers can then determine the duration of time the ignition needs to be and rear fenders and costs $11,450. The fairing alone is worth $5700, so straight-away if there is a drop-off in you now know why the accountants wince every time one of the bikes YZR has a sensor mind-boggling array of parameters. cut in order for the cogs to mesh dur- temperature or pressure. The first As well as the engine-management ing the gearshift. thing the computer guys check off system, you'll find the exhaust-valve the datalogger is this sensor to ensure motor and all other electronics all cylinders are running and working massed around that area to keep the in the same pattern." weight distribution to the front. Some of the key areas that it monitors are There is a switch on Biaggi's left han- through $36,000 worth of bodywork rpm, exhaust-valve movement and dlebar into which the team can pro- in a weekend. ignition timing, while there is a pres- gram settings for launch control. Biaggi and Checa have five sets of sure switch for the gear-shifter. "We download the information off When Biaggi leaves the line, he can flick the switch to prevent wheelies - bodywork for every race. And it's not just a convenient place to stick the conditions, but Biaggi always runs in a all the sensors and within seconds new set on Sunday morning ready for the race. The only time the engine is know what we can change to make when he reaches a rev limit, the engine-management system will cut sponsor's logos. As much wind-tunnel development goes into the fairing Pistons YZR pistons last 180 miles under race crashes. Last year, when Biaggi's teammate Carlos Checa was spend- Launch control ing more time in the gravel than on the tarmac, the team could get the bike better," Crust explained. "We in and reduce power. The system can as the airbox. Dummies are even also be used to tame the 190 hp bike used to mimic the exact riding posi- where only the crankcases are left in can program different settings from the laptop and send it directly to the in wet conditions. tion of Biaggi in order to achieve the the chassis is on Saturday night. engine-management system. We completely stripped down to the point optimum aerodynamics. "The current bodywork was tested have countless different programs for different tracks from data that we Carbs Cooling system on the track with Max," Crust have gathered at previous races and Biaggi's bike runs a main top radiator in testing." There are four 35mm Keihin carbs. Needle size and airscrew adjustment is for six months before we even put it explained. "We made four different with a smaller bottom radiator. uearbo1C critical to ensure that when Biaggi fairings in the middle of last year and Changes this year have increased the surface area and the water-flow into tested them in the wind tunnel to anatwo and spent another two months lyze which was· best. We then chose cracks open the throttle in mid-corner, the engine is responsive enough for The six-speed cassette-style the crankcases. The optimum water temperature range for Biaggi's bike is him to accelerate.smoothly. There is a gearbox gives the bike more than 80 60°C (140 degrees F). Sometimes testing them again." The bodywork is also rigorously throttle sensor on the carbs that monitors throttle position and revs, while settings from first to sixth gear, and subtle ratio changes can be made by the bottom radiator will be removed tested to make sure it doesn't distort. for cold conditions, but it is essential In the early days of carbon-fiber fair- the electronically controlled power-jet using information from the onboard for the bike to run in hot weather. system incorporates main, needle, datalogger. Crust said: "Because we "In those conditions, the sub radia- nozzle, pilot and pilot air jet. Biaggi's have so much info, long gone are the tor is used to keep water temperature engineers check outside temperature days when a rider will say he wants 5 at around 70° [157 degrees Fl." Crust mph lower or higher in any gear. We said. "Anything more and overheating can see on the data logger exactly causes a reduction in horsepower." and air pressure and cross-reference this data to air-correction charts to see if they need to change jets to suit the what rpm the bike is doing in a par- atmospheric conditions, which can ticular corner, so while Max might suggest something, we can be far vary dramatically from a morning warm-up session to the race. more accurate when we alter the ~Exh.ust system Biaggi's bike has four different gearing." ings, the force of the wind buckled them. ~Aerod .,;;;a,;,;m.;,;i;";;c.;;s_ _",,, All that testing is crucial because aerodynamics are such a fundamental factor in a 500's performance. Six months or more go into the design, titanium exhaust systems, all with carbon end-cans. These options give tracks with long straights like Suzuka, different power characteristics to suit Mugello, Catalunya an the various circuits. Just the bottom Clutch The carbon-fiber airbox is a very but that can make all the difference on the track. Biaggi's bodywork at worth around 1.5 mph on top speed. Valencia is complex component. Yamaha carries The multi-plate dry clutch is the set of pipes costs up to $14,000 and "The problem is that you think you out extensive wind-tunnel tests using same as those fitted to the other the carbon cans are fitted with a tita- can improve the straight-line speed transparent airboxes so they can see the air flow in the cavity. But wind- works YZRs, but Biaggi's has a lighter nium insert to keep weight down and with trick bodywork, but the bike operation at the lever to suit his personal preference. to aid heat transfer through the might not want to go around a corner," Crust said. "That's what we bat- tunnel testing doesn't tell the whole story, since the static tests are carried "It's crucial for Max to get a con- exhaust. While pipes from number one, three and four cylinders are out with Biaggi's bike bolted upright. Wind speed into the intakes changes sistent feeling from the clutch to straight and fairly simple to make, cowling and seat for this year. To make sure he is confident at the start," Crust said. "That's why he the number-two pipe has to form an S-bend and is the one engineers are redesign a cowling that is still effective on the track, but doesn't alter the practices so many starts, so he can continually trying to improve - the feeling of the bike to the rider, takes a get a feel for the motor getting hooked up in first gear." smoother the gas flow through here, hell of lot of development work to the more power they can glean. achieve." when the bike is cranked over - and a wind tunnel can't simulate dust and debris that may get thrown into the sealed box. This means that once the airbox is developed in the tunnel, the team has to carry out on-track testing to perfect the component. 20 AUGUST 15, 2001 • eye I • n e _ s tled against when we developed the

• Cover