3
Pipe 3 (Fuel Supply) goes from the long end of the Y connector to the carburettor
in
union.
Pipe 4 (Fuel Return) goes from the remaining short end of the Y connector (with 70 jet) to the new fuel tank
union. This is the fuel return pipe.
Pipe 5 (Breather Pipe) goes from the tank to act as a breather – ideally located into a high mounted catch
tank. The Y connector should be located as high as possible on the kart just between the engine and the
condenser pot bracket. The Y connector arm with return jet inserted should be highest of all. This helps to
remove trapped air from the pipes. All of the pipes when trimmed to length and connected must be cable tie
neatly in position without deforming or reducing their internal bores which could cause fuel starvation.
Warning: Ensure that all fuel pipes cannot chafe or rub against other parts which could cause a fuel leak.
Note that the blue pulse pipe from the engine brass pulse union located under the inlet manifold goes to the
rearward facing brass pulse union on the pulse pump.
Step 6
Check the alignment of the axle sprocket with the clutch sprocket teeth, adjusting as necessary ensuring
that you have sufficient axle key located in the sprocket carrier. Remember that you will need less teeth on
the rear sprocket than with a two-stroke. Try 12T: 68T as a good starting point. If the sprocket carrier does
not have sufficient location on the key then it can always be turned around so its offset can cover the key.
Once complete, fit chain and adjust (12mm of total up & down movement) ready for use, remembering to
fully tighten the clamp bolts. Finally adjust fitment of the fully enclosed plastic chain guard to ensure it does
not rub against the exhaust and it is spaced out from axle bearing to suit the chain alignment.
Step 7
Fit the exhaust onto the manifold with both securing springs and also locate with springs onto exhaust cradle
mount.
Warning: The position of this exhaust cradle MUST be adjusted to ensure a natural fit with no tension on
the exhaust manifold. If this is not done then the exhaust manifold pipe may touch plastic float
bowl on carb during running which will cause dangerous fuel leaks.
Please note a special Exhaust Manifold and Cranked Exhaust is available for
Pro-Karts
with brake discs
located in the centre of the axle.
Step 8
Fit noise box to carb inlet with the twin air inlet filters facing approximately downwards. Note you will need a
bracket to secure the noise box from its mounting bush to a suitable location such as a securing bolt on the
rear axle bearing. Tal-Ko offer a bracket set for its own karts, though every make of kart will require
something different. It is vital to use such a support bracket and the noise box must always be supported
firmly in a natural position with no pull on carb as this will cause the carb rubber inlet connector to engine to
fracture.
Step 9
The carburettor throttle cable will need fitting to the slide of the carb. Simply remove the carb top (2 Bolts)
remove slide assembly and push cable through cable swan neck, large spring and outer small hole in needle
retaining plate. Place end of cable into the slide cable slot and reassemble carb top. Then thread through
outer cable and connect to the pedal. It is important to ensure that the pedal locates against a bolt at full
throttle to prevent damage to the carb or pull on the rubber inlet connecting manifold.
Warning: The carburettor throttle cable must not be kinked or restricted as the carburettor slide might
stick in full throttle open position.
Step 10
Next connect the ignition on/off switch. This can be fitted anywhere suitable, though we provide with the
engine a bracket that allows you to fit switch on the M8 bolt holding the upper plastic steering column bush to
chassis just above the tank. It may well require a new longer length bolt when this bracket is fitted to allow
the bolt to fully enter the Nyloc part of its securing nut.
Connect a red wire from the switch to the spare red short lead coming off the coil unit. Another lead must be
earthed from the switch to the engine coil earth lead bolt. If this earth is not good then the switch will not
