Tomberlin CrossFire 150 Service Manual Download Page 12 | Manualshive

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WARNING:

Do NOT open sealed caps to add water to the battery.

- Batteries contain sulfuric acid. Eye protection should ALWAYS be used when working around battery acid.

-

While attaching the red and black cables for charging, be sure that the charger is not plugged into the outlet.

- Charge the battery in a well ventilated area out of reach of children and animals.
- Do NOT smoke around batteries
- Do NOT expose batteries to open fl ames

CHARGING THE BATTERY

- The battery must be charged before use.

- Connect the positive (+) red clamp from the battery charger to the positive (+) pole of the battery.

- Connect the negative (-) black clamp from the battery charger to the negative pole of the battery.

- Do NOT plug the charger into the outlet until the clamps have been placed in their proper location on the
battery.

- The battery should charge between 500-700 milliampere for 6-10 hours.

- When the battery has fi nished charging, unplug the charger from the outlet, then proceed to remove the
clamps from the charger.

Note: Always keep the battery clean. Apply dielectric grease around the battery terminals to prevent corrosion.

INSTALLING THE BATTERY

- Place the battery into the battery tray located in front of the engine on the passenger’s side. Be sure that the
rubber mat is laying on the bottom of the tray between the tray and the battery.

- The warning label on the battery should be facing the rear of the kart when installing.

- Be sure to connect the positive side of the battery before connecting the negative side.

- Attach the positive (+) red wire to the positive terminal on the battery. Attach the negative (-) black wire to
the negative terminal on the battery.

- Cover the battery with the grey cover. Be sure to slide the wires through the openings in the cover.

- Secure the battery into place using the hooks on both ends of the strap. Strap comes with two hooks to fi t
replacement batteries. For the provided battery, use the middle hook. Fold the excess strap against the battery
and attach remaining two hooks to their contact points. Utilize the proper hooks depending on battery size.

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Summary of Contents for CrossFire 150

Page 1: ...CrossFire 150 Service Manual ...

Page 2: ...rt 11 Valve Clearence Inspection 12 Valve Mechanism Inspection and Servicing 13 Cylinder Head Removal Installation 13 Camshaft 14 Cam Chain 17 Rocker Arm and Rocker Shaft 18 Valve and Valve Spring 18 Cylinder 23 Piston 24 Crankcase and Crankshaft Removal 26 Crankshaft Inspection 27 Crankshaft and Crankcase Installation 28 Lubrication System 29 Oil System 30 Transmission Diagram 32 i ...

Page 3: ...moval 48 Rear Sprocket Removal 49 Axle Bearing Removal 49 Swingarm 49 Charging System 50 Ignition System 54 Electrical Starting Mechanism 58 Armature Inspection 59 Carbon Brush Inspection 59 Starter Motor Installation 59 Starter Clutch 60 Reduction Gear Inspection 60 Engaging Mechanism 61 Brakes 62 Rear Brake Inspection 63 Front Brake Inspection 65 ii ...

Page 4: ...Brake Bleeding Fluid Change 66 Rear Brake Disk Removal 66 Front End Adjustments 67 Adjusting the Shocks 68 Wiring Diagram 69 Notes 70 iii ...

Page 5: ...on to comfort using the lever under the driver s seat Flip green ON OFF switch to ON position The foot brake must be depressed while attempting to start the go kart With brake still depressed start the engine by turning the key clockwise Note Engine will not turn over unless brake pedal is depressed To immediately stop the engine flip the green ON OFF switch to the OFF position WARNING The exhaust...

Page 6: ... quarter 3 4 throttle for long periods of time Vary the throttle during operation and avoid maximum acceleration Allow the engine to cool for ten minutes after each 1 5 hours of operation After 20 hours Vary acceleration while driving Do Not use full throttle for long periods of time Allow the engine to cool occasionally during long periods of operation Change the engine oil after the first 5 hour...

Page 7: ...sis Inspect Inspect Fasteners Inspect Inspect Brake Performance Inspect Inspect Brake Fluid Inspect Air Filter Change Carburetor Inspect Inspect Spark Plug Change Drive Chain Inspect Inspect Inspect Adjust Engine Oil Replace Inspect Replace Gearbox Oil Inspect Replace Valve Clearance Adjust Fuel Line Inspect Inspect Inspect Exhaust Inspect Inspect Battery Inspect Inspect Interval Months Service Da...

Page 8: ...ck oil level to see if it is between min and max indicators Add oil as necessary to reach the required level Return the dipstick to its original position Be sure to tighten the cap into place after checking the oil CHANGING THE ENGINE OIL Run unit for at least 5 minutes or until warm shut off Place suitable container for draining oil beneath engine Container should be capable of holding at least 1...

Page 9: ...ents will be extremely hot after the kart has been running Use extreme caution when working on an engine that has been in use Note API Service Standard GL 5 GL 4 GL 3 SAE 80W 90 gear oil is recommended in the final drive case How ever in extreme cold weather conditions it is advised that a lighter viscosity oil such as 75 weight oil be used Final drive capacity 115 cc 4 oz SPARK PLUG NGK C7HSA Cle...

Page 10: ...e the battery on a level surface and remove the metallic sealing from the top Holding the electrolyte container upside down so the sealed openings are facing the ground align each sealed opening of the bottles with the corresponding openings on top of the battery terminal Strongly push the electrolyte container into the openings of the battery terminal so that the all of the seals on the electroly...

Page 11: ...ter battery performance Place the cap strip loosely over the holes in the top of the battery while allowing it to sit After sitting for thirty 30 minutes the battery is ready for charging Push the caps firmly into the holes Do not pound or hammer on the caps to force them into place This will seal the battery Do Not attempt to remove the caps after sealing the battery 1 2 3 4 5 6 7 8 7 ...

Page 12: ... outlet then proceed to remove the clamps from the charger Note Always keep the battery clean Apply dielectric grease around the battery terminals to prevent corrosion INSTALLING THE BATTERY Place the battery into the battery tray located in front of the engine on the passenger s side Be sure that the rubber mat is laying on the bottom of the tray between the tray and the battery The warning label...

Page 13: ...T BATTERIES YUASA YTX7L BS 12 Volt 6 Amp 85 Cold Cranking Amps 4 1 2 in Long x 2 13 16 in Wide x 5 1 16 in Tall YUASA YTZ7B BS 12 Volt 6 Amp 90 Cold Cranking Amps 4 1 2 in Long x 2 13 16 in Wide x 5 3 16 in Tall YACHT CT7B 4 12 Volt 6 5 Amp 90 Cold Cranking Amps 4 1 2 in Long x 2 13 16 in Wide x 5 3 16 in Tall POWER MAX GTX7L BS 12 Volt 6 Amp 90 Cold Cranking Amps 4 1 2 in Long x 2 13 16 in Wide x...

Page 14: ...emove the 5 screws on air filter and remove the cover Remove the 3 screws of the air filter and remove element Clean the air filter cover with a mild soapy water mixture Rinse and allow to dry Do Not attempt to clean the air filter Install a new air filter and reattach cover Tighten screws NOTE Before and during service inspect the air filter for rips A torn air filter must be replaced Make sure t...

Page 15: ...TENING TORQUE CHART Tables FASTENER Thread Size TORQUE ft lbs in lbs T O R Q U E Nm 5 mm bolts and nuts 39 52 in lbs 4 5 6 Nm 6mm bolts and nuts 69 104 in lbs 8 12 Nm 8mm bolts and nuts 13 18 ft lbs 18 25 Nm 10 mm bolts and nuts 22 29 ft lbs 30 40 Nm 12 mm bolts and nuts 36 43 ft lbs 50 60 Nm 4 mm screws 22 30 in lbs 2 5 3 4 Nm 5mm screws 30 43 in lbs 3 5 5 Nm 6 mm hex bolts 87 121 in lbs 10 14 Nm...

Page 16: ...sprocket must be aligned with the cylinder head surface Cam lobes must be pointing downward Cam timing Loosen the lock nuts on tappet screws to adjust valves To adjust the valves use a valve adjusting wrench To decrease valve clearance turn tappet screw clockwise To increase valve clearance turn tappet screw counterclockwise Use a thickness gauge to measure the valve clearance to 0 003 0 005 in Ta...

Page 17: ...OVAL Remove carburetor Remove exhaust Remove fan shroud assembly Remove cylinder shroud assembly Remove valve cover Remove Phillips screw and O ring from cam chain tensioner Insert small straight screwdriver and turn clockwise until spring loaded tensioner locks This allows slack in cam chain for removal of cam shaft 1 Remove the 2 bolts and 4 flange nuts and washers Remove cam shaft holder and do...

Page 18: ...tened gradually in 2 3 times diagonally After installing adjust the valve clearance Torque the cylinder head nuts and bolts Bolts 95 in lbs Nuts 16 ft lbs Insert small straight screwdriver and turn the cam chain tensioner bolt counter clockwise and release the lock Do NOT tighten Apply oil on the new O ring Install and tighten the cam chain tensioner cover bolt The O ring must be mounted properly ...

Page 19: ... any damage on the cam surface If the cam surface appears to be excessively damaged replace it Measure the height of the cam lobes Intake Lobe 25 960 mm 1 022 in Exhaust Lobe 25 815 mm 1 016 in CAMSHAFT INSTALLATION Align the T mark on the flywheel with the index mark on the engine case by turning the flywheel Position the camshaft gear with cam chain so that timing marks on sprocket align with th...

Page 20: ...ts 95 in lbs Nuts 16 ft lbs Insert small straight screwdriver and turn the cam chain tensioner bolt counter clockwise and release the lock Do NOT tighten Apply oil on the new O ring Install and tighten the cam chain tensioner cover bolt The O ring must be mounted properly in the groove 16 ...

Page 21: ... cam chain tensioner is a spring loaded device and should not need to be adjusted unless you are re moving and installing camshaft CAM CHAIN PARTS BREAKDOWN 1 Cam chain 2 Cam chain tensioner 3 Cam chain tensioner lifter 4 Gasket 5 Cam chain tensioner pivot 6 Cam chain guide 7 Bolt 8 Nut 9 O ring 10 O ring The operational principle of the tensioner is as shown in the picture below 17 ...

Page 22: ...spected for damage to the cam lobe Measuring the inner diameter of the rocker arm Service limit 10 10 mm 0 398 in Measuring the outer diameter of the rockershaft Service limit 9 91 mm 0 390 in ROCKER ARM AND ROCKERSHAFT INSTALLATION The camshaft holder has EX stamped on the exhaust side Pay close attention when installing rockers and rocker arm shafts because the shafts are different Note apply so...

Page 23: ... mm 1 930 in Measuring the free length of the inner and outer valve spring Valve Inlet Valve Exhaust Valve Inner spring 31 2 mm 31 2 mm 1 228 in Outer spring 34 1 mm 34 1 mm 1 342 in VALVE AND VALVE SPRING INSTALLATION Mount the spring retainer valve guide oil seal Replace the valve guide oil seal with a new one After applying oil on the valve stem mount it into the valve guide Mount the inner and...

Page 24: ...ice limit Inlet valve Exhaust valve 0 08 mm 0 10 mm 0 0035 in 0 004 in If the abrasion of the valve guide exceeds the service limit it should be replaced After installing a new valve guide the valve seat must be reconditioned VALVE GUIDE REPLACEMENT Heat the cylinder head to 212 F 302 F 100 C 150 C Note The cylinder head must be heated quickly and in its entirety Warping may occur if it is heated ...

Page 25: ... the valve seat width to be uneven too wide or too narrow it will result in bad contact between the valve and the valve seat and the seal will not be tight When this happens the valve seat must be reconditioned with a customized valve seat milling cutter The valve seat milling cutter is a customized trimming tool for the valve seat It has three cutting angles 32 45 and 60 VALVE SEAT FINISHING Ream...

Page 26: ... seat should be lapped Notes Before lapping clean up the valve valve seat and valve guide When lapping do not use too much force press down the valve suction cup lever gently During lapping do not drop any lapping compound into the place between the valve lever and the valve guide Lapping the valve seat Spread a thin layer of lapping compound on the working bevel of the valve Use a valve suction c...

Page 27: ...ylinder for evidence of warping using a straight edge and feeler gauge Service Limit 0 04 mm 0 002 in Inspect cylinder for wear scratches or damage Inspect cylinder for taper and out of round Measure in two different directions front to back and side to side on three different levels 1 1 2 down from top 2 in the middle 3 1 2 up from bottom Record measurements If cylinder is tapered or out of round...

Page 28: ...ston pin and piston pin hole should be checked again to ensure compliance with the proper diameter MEASURING THE INNER DIAMETER OF PISTON PIN HOLE Service limit 15 04 mm 0 5925 in If the result is more than the service limit replace the piston INSPECTION AND SERVICING PISTON RINGS Measure piston ring to groove clearance by placing the ring in the ring core and measuring with a thickness gauge Repl...

Page 29: ...ed PISTON RING INSTALLATION GAP Apply oil on every piston ring Enlarge piston rings while placing them on the piston and move downwards gradually until piston rings fall into ring groove PISTON INSTALLATION Mount piston onto the small end of the connecting rod Apply oil on the piston pin to lubricate it Place a piece of cloth on the crank case port to prevent the piston pin clip from dropping into...

Page 30: ...ve the piston 9 Remove the drive clutch 10 Remove the AC generator 11 Remove the starting motor 12 Remove the right hand crankcase cover 13 Remove the oil pump 14 Remove the starter clutch 15 Remove the starting driven gear 16 Remove all crankcase bolts 17 Separate the right crankcase and the left crankcase 18 Remove the gasket and the dowel pins 19 Remove the crankshaft from the crankcase 20 Clea...

Page 31: ...ort connecting rod against one side of crank shaft and apply up and down pressure on connecting rod Read total movement of indicator and compare to specifications Replace crankshaft if clearance is excessive Service limit 0 05 mm 0 002 in MEASURING THE RUNOUT OF THE CRANKSHAFT Support crankshaft with V blocks Setup up dial indicator on end of crankshaft Rotate crankshaft and measure runout Runout ...

Page 32: ...t into the left crankcase Do not allow the cam chain to damage the oil seal Mount the new dowel pins and gasket on the left crankcase joining the right crankcase and the left crank case together Tighten the crankcase bolts Tightening torque 0 9 kg m 78 in lbs Install the starter clutch Reassemble in reverse order of disassembly 28 ...

Page 33: ... the oil pump Some of the oil goes into the big end of the connecting rod and splashes on the cylinder wall and the small end of the connecting rod Another amount of oil goes through some oil passages such as the shaft neck of the camshaft and splashes on the cam rockershaft and cam chain The picture is a functional diagram of the lubrication system 29 ...

Page 34: ...driving gear and chain Remove the oil pump positioning bolts and the oil pump assembly Remove the screw and disassemble the oil pump OIL PUMP INSPECTION Inspect the clearance between the oil pump body and the outer rotor Service limit 0 12 mm 0 005 in Inspect the clearance between the inner rotor and the outer rotor Service limit 0 12 mm 0 005 in Inspect the clearance between the rotor plane and t...

Page 35: ... be up wards Tighten the oil pump positioning bolts to 95 in lbs Align the oil pump driving gear with the oil pump shaft Install the driving gear and chain Install the driving gear positioning nut and tighten it to 95 in lbs Install the partition board and tighten bolts to 87 in lbs Install the starting reduction gear and starting clutch left handed threads Install the gasket and dowel pins Instal...

Page 36: ......

Page 37: ...INSPECTION Note Use a level surface when inspecting the oil level of the transmission case Inspect if there is oil leaking around the transmission case After the engine stops remove the transmission case oil viewing bolt Observe the oil level when the oil level is parallel with the observing hole When the oil level is too low use the appropriate oil and add until oil flows from the level screw Mou...

Page 38: ...viscosity oil such as 75 wt Final drive capacity 115 cc 4 oz TRANSMISSION CASE TRANSMISSION CASE REMOVAL Remove the driven belt pulley Drain the oil from the transmission case Remove the drive sprocket Remove the bolts and remove the transmission case cover Remove the gasket and dowel pin Remove the final gear from the output shaft and remove the counter shaft TRANSMISSION CASE GEAR INSPECTION Ins...

Page 39: ...case if it is worn or damaged Remove the oil seal Drive out the final gear shaft bearing Remove the sub shaft bearing Remove the driven belt pulley shaft bearing Drive in the new driven belt pulley shaft bearing Drive in the new sub shaft bearing Drive in the new final gear shaft bearing Install the driven belt pulley shaft on the transmission case cover Drive in the transmission case cover oil se...

Page 40: ... Mount the drive pulley the transmission belt and the left crankcase cover Add 80W 90 gear oil in the transmission case until it gets to the proper level Gear Oil Amount 115 cc ml 4 oz 36 ...

Page 41: ...s mounted on the engine crankshaft and the driven belt pulley connects with the rear driven mechanism When the diameter of the driving belt pulley changes from small to big proportionally the diameter of the driven belt pulley changes from big to small because the perimeter of the driven belt is constant The structure of the driving belt pulley is shown in the picture below The picture shows the w...

Page 42: ...ate set Remove the ramp plate Remove the centrifugal rollers DRIVE BELT PULLEY INSPECTION Inspect if there is any damage to the centrifugal roller Measure the outer diameter of the centrifugal roller Service limit 17 0 mm 0 6695 in Measure the inner diameter of the movable drive plate Service limit 24 06 mm 0 947 in Inspect if there is any damage to the drive plate hub Measure the outer diameter o...

Page 43: ...injury on the clutch drum Measure the inner diameter of the drum Service limit 125 5 mm 4 941 in Inspect if there is any abrasion or injury of the clutch centrifugal weight friction piece Measure the thickness of the clutch shoes Service limit 1 5 mm 0 059 in CLUTCH DISASSEMBLY When the centrifugal weight set needs to be replaced the clutch must first be disassembled Note If the drum is seriously ...

Page 44: ...uide pin the roller and the movable driven plate Remove the oil seal on the movable driven plate DRIVEN BELT PULLEY INSPECTION Measure the free length of the driven belt pulley spring Service limit 163 7 mm 6 420 in Inspect if there is any abrasion or damage on the driven plate Measure the outer diameter of the driven plate pulley hub Service limit 33 94 mm 1 3365 in Inspect if there is any abrasi...

Page 45: ... plate with its front face upwards Mount the circlip Using the appropriate grease apply lubricant evenly on the inner wall of the driven plate Drive the new needle bearing in with its mark pointing upwards Apply grease around the bearing DRIVEN BELT PULLEY INSTALLATION Clean the driven plate of grease Install the oil seal Apply a small amount of grease on the O ring Install the movable driven plat...

Page 46: ...hen replacing DENI CARBURETOR PD24JH CARBURETOR REMOVAL Turn fuel to OFF position Remove throttle cable choke wire fuel line and vacuum line Loosen clamps on intake manifold and air filter Remove carburetor CARBURETOR DISASSEMBLY AND INSPECTION Remove the four screws on float bowl and remove float bowl Check float bowl for dirt and fuel residue Remove float float needle valve main jet needle jet h...

Page 47: ...dy of carburetor and inspect seal Remove the two screws holding vacuum pod to body Remove spring and pod inspect pod for tares or holes Remove air adjusting screw spring washer and o ring Inspect air adjusting screw tip and o ring for damage 43 ...

Page 48: ...contact cleaner to check passages in body making sure that they are not obstructed Use low pressure air to dry all components CARBURETOR ASSEMBLY Replace parts in proper order Install pilot jet needle jet jet holder and main jet Install needle valve with float sliding pin locating in place Check float level by placing carburetor at angle so that float adjustment tab contacts needle valve Float sea...

Page 49: ... minutes and engine is at operating temperature so that cold enrichment system has had time to set Idle speed needs to be set at 1750 100 RPM CARBURETOR STARTER SYSTEM CHOKE OR ENRICHMENT This carburetor is equipped with an automatic enrichment system that is controlled by the charging system After engine is started the charging system supplies voltage to solenoid on carburetor causing solenoid to...

Page 50: ...distance from the base of solenoid to sealing edge of plunger Connect a good 12 volt battery to the solenoid using jumper wire for 5 minutes and measure the distance again Cold 11mm 433 in Hot 14mm 552 in WARNING Solenoid becomes hot during testing Inspect O ring on solenoid for damage Install plunger into mount making sure that plunger moves freely in mount Install assembly on carburetor 46 ...

Page 51: ... Float level to high Faulty float needle valve Loose jets Worn jet needle or needle jet Dirt in air passages LEAN MIXTURE Symptoms Hard starting popping through intake low power runs hot detonation surging idle speed erratic Possible causes No fuel in tank Fuel tank not venting Carburetor vent restricted Clogged jets or air passage Float level to high Air filter not sealing Intake leaking Air mixt...

Page 52: ... ADJUSTMENT Loosen the jam nuts Turn adjustments nut clockwise to remove deflection Leave 3 8 3 4 in deflection in chain LUBRICATION OF CHAIN Lubricate chain after every use while chain is still warm Only use O Ring safe chain lubrication for the chain on this go kart REAR AXLE REMOVAL Raise and secure rear end of the machine Remove cotter pins on rear axle nuts Remove axle nuts Remove rear wheel ...

Page 53: ...bearing from bearing housing and inspect bearings and seals for damage Pack bearing in grease before installing Torque axle bearing bolts 18 ft lbs SWINGARM Note Swing arm axle and motor can be removed as a unit if needed Remove shock absorbers Remove rear brake caliper and set aside Do NOT remove brake hose Unplug wiring from the electrical box Remove throttle cable Remove bolts from swingarm piv...

Page 54: ...ry Connect the negative end of the meter with the ground wire Test the electric drain In general the number should be less than 1 mA Inspect for a short circuit of the igni tion switch and the main wiring harness CHARGING STATUS INSPECTION Install a fully charged battery Connect the voltmeter to the battery Remove the fuse and connect the meter with two ends of the fuse Connect the tachometer with...

Page 55: ... Connect the negative pole of the charger with the negative pole of the battery Charge the battery for the charging time indicated on the battery Recheck the voltage after 30 minutes of charging If it still below 13 1 V continue to charge at 15 minute intervals checking voltage levels for the appropriate charge Continue as needed Normal Fast Charging current 0 7 A hr 3 0 A hr Charging time 5 10 ho...

Page 56: ... work can be done on the engine without removing the generator Remove the 4 pin connector of the generator Remove the 2 bullet connectors Measure the resistance value between the wire and engine ground White 0 2 0 4Ω 20º C Yellow 0 1 0 8 Ω Blue Yellow148 Ω Black Red 502 Ω Black When the measured value is more than the standard value the coil should be replaced 52 ...

Page 57: ...the flywheel nut Remove the flywheel with a flywheel puller and remove the solid key Remove the generator wire connector GENERATOR INSTALLATION Reverse the removal procedure for installation When installing the flywheel make sure there are no metal pieces such as bolts or nuts attaching to the inner wall of the flywheel After the installation is finished start the engine and inspect the ignition t...

Page 58: ...timing Remove the ignition timing hole cover or remove the fan cover Rotate the generator rotor and align the F mark on the rotor with the crankcase timing ignition mark Clip the ignition timing indicator light wire clip on the high voltage end of the ignition coil Start the engine and keep it in idling condition Observe if the mark on the crankcase aligns with the F mark on the rotor Slowly incre...

Page 59: ... value of every coil should be the standard value Inspect the resistance value between every CDI component terminal If the actual value is not in the range of the value in the chart then the CDI component is faulty CDI Component values displayed in KW Negative POSITIVE SW B W EXT B R PC G R E G or G W IGN B Y SW B W 100 50 100 EXT B R 0 5 50 100 PC G R 10 1000 10 1000 1 100 E G or G W 0 5 50 0 5 5...

Page 60: ...ndicates the coil is broken Remove the spark plug cap and measure the resistance value of the secondary ignition coil Standard Value 2 4Ω 20º C SPARK PLUG NGK C7HSA Clean up the carbon around the spark plug to prevent it from dropping into the cylinder when removing the spark plug Remove the spark plug Note When installing connect the black yellow wire of the primary ignition coil with the black y...

Page 61: ...rging coil the white wire Negative to ground Generally 0 2 2 0 To check the regulator rectifier W White Y Yellow R Red G Green W White 3 100 K Y Yellow 5 100 K R Red G Green 5 100 K REGULATOR RECTIFIER INSPECTION Inspect the regulator rectifier connection Measure the resistance value between every regulator rectifier terminal If the resistance value between the terminals does not match the value i...

Page 62: ...ove the starting relay inlet line the green yellow line Connect the yellow red line with the ground wire and press the start button It should be conductive between the yellow red line and the ground wire or the start button is bad STARTER MOTOR The starter motor is a direct current DC motor Its structure is shown in the picture below 1 Starting gear holder 3 Carbon brush spring 3 Gasket 4 Starting...

Page 63: ...aced CARBON BRUSH INSPECTION Inspect the insulating condition between the connecting wire terminal and the starter motor case It should be non conductive Inspect the conducting condition between the connecting wire terminal and the carbon brush It should be conductive Inspect brush set for excessive wear or damage Measure the insulating condition of the carbon brush bracket It should be non conduc...

Page 64: ... the lead wires and inspect if the motor can run normally Apply oil on the O ring and install the starter motor Tighten holding bolts STARTER CLUTCH This picture shows the structure of the starter clutch 1 Starter reduction gear 2 Starter reduction gear shaft 3 Starting clutch gear comp 4 Starting clutch outer comp 5 Flange starting clutch 6 Starting clutch roller spring 7 Spring holder 8 Starter ...

Page 65: ...hly The driving gear should lock when turned counterclockwise Inspect if there is any abrasion or damage on the surface between the driving gear and the needle bearing It should be replaced when the surface is unusual Measure the inner diameter of the driving gear It should be replaced when the diameter is more than the ser vice limit Service limit 32 06 mm 1 2625 in Inspect the condition of the n...

Page 66: ...d the driving gear and put the outer clutch component on Align the groove of the woodruff key on the crank and install the starting clutch Apply some oil on the reduction gear and the reduction gear shaft then install Hold the drive while simultaneously fastening the clutch nut Install the right crankcase cover Install the left crankcase cover BRAKES BRAKE PERFORMANCE Always check that there is pl...

Page 67: ...rame Remove both outer plugs Remove brake pad pins and remove brake pads Check thickness of pads and replace if out of service limit Service Limit Measuring thickness without backing plate 2 0 mm 0 080 in Measuring thickness with backing plate 3 0 mm 0 120 in ...

Page 68: ...ing rust or corrosion Lubricate brake mounting pins with grease and reinstall caliper on mounting plate Check for proper move ment of caliper on pins Make sure to not get grease or oil on brake pads or rotor Install new pads making sure shoe spring is in place 64 ...

Page 69: ...rvice Limit 3 0 mm 0 120 in FRONT BRAKE INSPECTION The process for inspecting the front brakes is the same as the process for inspecting the rear brake NOTE If inspecting the front brakes be sure to inspect the brakes on each side of the kart The front brakes are attached to the spindle on each side not the frame 65 ...

Page 70: ...ng pedal pressure open bleeder valve To bleed air off close valve Repeat procedure until all air has been purged from system and clean fluid appears Note Maintain fluid in reservoir while performing procedure REAR BRAKE DISK REMOVAL Remove the rear axle Remove four bolts holding disc to axle Visually inspect disc for wear or damage If measurements fall beyond service limit replace disc Service Lim...

Page 71: ...FRONT END ADJUSTMENTS CASTER 1 Inch CAMBER 1 Inch TOW The cart should have 1 Inch of tow after the front tires have been centered 67 ...

Page 72: ... the shock will change depending on the way that it is rotated To increase the tension rotate to the right to decrease the tension rotate to the left It is important to adjust the shocks to correspond to the weight of the riders Do NOT attempt to operate this kart if the shocks in the front are not on the same settings or if the shocks in the back are not on the same settings 68 ...

Page 73: ... 4 2 2 52 4 2 34 24 2 2 9 34 24 2 2 5 4 2 2 4 2 37 4 0 0 4 4 0 53 44 29 30 2 0 5 2 3 34 2 9 7 9 7 2 9 7 2 9 7 2 9 7 2 9 7 2 9 7 2 9 7 2 2 9 7 9 7 9 7 9 7 9 7 2 2 2 2 2 2 2 2 2 2 2 2 2 2 5 0520 5 9 7 4 2 2 5 7 4 7 4 7 4 7 4 2 7 4 2 2 2 2 2 WIRING DIAGRAM ...

Page 74: ...Notes 70 ...

Page 75: ...Notes 71 ...

Page 76: ...3123 Washington Road Augusta GA 30709 1 877 855 0196 www tpg info com ...

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