TKM K4S Installation & Running Manual Download Page 4

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operate. Ensure both wires are neatly secured with cable ties or PVC tape. Remember to clearly mark the
On/Off positions.

Step 11

A radiator coolant catch tank must be used. It can be fitted in between bottom of radiator and engine near
clutch guard using a cable tie on bottom radiator bracket on standard engine mounted radiator or on the
bracket designated for it with the larger brake side mounted Enduro Radiator.

Warning: Please follow the instruction of the chassis manufacturer for mounting the water coolant hoses

to the chassis if available.

Warning: For Enduro radiator installation to the chassis please follow the instruction of the chassis

manufacturer if available.

Enduro Radiator (Optional)

In very hot weather or warm climate countries we advise use of the optional Enduro style radiator system.
This comprises of a larger radiator fitted to the brake side of kart. Tal-Ko supplies the full kit which includes
radiator, pipes and mounting brackets. The use of an inline thermostat is also advised with this radiator. This
thermostat is not included in the kit and can also be purchased from Tal-Ko.

Warning: The engine temperature should not exceed 90C as exceeding the engine temperature could

lead to serious engine failure.

Picture shows an Enduro type radiator fitted to kart.

Step 12

You will need to drill/cut holes in both the outside and inside faces of the sidepod to allow access for the
remote hand held starter shaft.

Please note

that if you wish to install a temperature gauge then the sensor MUST be located in the special

location hole provided at the top of the engine. This will have an M10 x 1 taper plug in place which should be
removed and the sensor fitted with PTFE tape to prevent leakage.

Summary of Contents for K4S

Page 1: ... hour with minimal needs Warning Identifies an instruction which if not followed may cause injury or endanger the life of the driver mechanic or third party or may cause damage to your TKM K4S engine General precaution and safety information for engine installation running Warning For the best possible engine operation compliance with the following advice regarding installation of engine and equip...

Page 2: ...smooth steady fall on the pipe from condenser to engine Trim if required and cable tie Without this steady fall oil will collect in pipe and restrict oil returning to engine The larger bore plastic pipe should run straight up from the engine and then naturally over the top of the carb inlet manifold and across to the condenser pot union with a steady rise if possible Again trim if required Secure ...

Page 3: ...ral 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 ...

Page 4: ... use of the optional Enduro style radiator system This comprises of a larger radiator fitted to the brake side of kart Tal Ko supplies the full kit which includes radiator pipes and mounting brackets The use of an inline thermostat is also advised with this radiator This thermostat is not included in the kit and can also be purchased from Tal Ko Warning The engine temperature should not exceed 90C...

Page 5: ...brake side mounted optional Enduro type radiator which is recommended for hot climates then a much lower temp range of 60 65C can be achieved If the engine does not reach the minimum specified operating temperature of 50C due to the low ambient temperature then the cooling efficiency of the radiator must be reduced by partially covering the radiator with adhesive tape or similar Note that above ap...

Page 6: ...r the running in period for racing the use of Castrol EDGE Sport 0W 40 or other equivalent high quality specification synthetic oils is recommended Warning Do not run the engine with incorrect grade oil as this will lead to engine failure Warning Do NOT use motor cycle type oils Oil Change We recommend draining the oil and changing for fresh after every 90 minutes of engine use Some drivers may ch...

Page 7: ...een set to give an approximate setting for first starting running However it will probably need the tickover speed fine tuning once first started On the top of the carb is the small black plastic choke lever which can be pulled upright to give full choke This should be used in the full choke position to first start the engine from cold Do not depress the throttle when starting on choke as it may c...

Page 8: ...earing protective clothing for kart operation First with the driver sitting in the kart ensure that the ignition switch is off Then engage the remote hand held starter shaft firmly on the crank nut and hold the starter firmly With the ignition in the off position you should then spin the starter for three or four short 2 second bursts just to ensure that the oil has been pumped around the engine W...

Page 9: ...ve periods of 15 minutes 0 15 minutes Use minimal throttle starting at first around 4000rpm and do not exceed 5000rpm Use the throttle to power on and off during all of the running in periods Do not hold engine at constant speed but vary up and down Keep a careful eye on the temperature gauge It is a good idea to put one or two pieces of tank tape at the top across the full width of the radiator I...

Page 10: ...ns is that the engine will not rev above 11950rpm but it does not cut out We advise you not to run for any length of time with the limiter operating Always start with small axle sprockets to establish correct RPMs and then increase or decrease as required For tracks with long straights we advise possible use of a 13 tooth clutch sprocket Clutch This specially designed unit has been made with long ...

Page 11: ...Not Do Start the engine without circulating priming the oil first with ignition turned off if engine has been left standing for more than 2 hours Leave the engine ticking over with the choke out for long periods it will cause piston and bore wear Rev the engine while standing still premature clutch wear and overheating will result Run the engine without having the correct levels of water coolant o...

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