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Torini TC210 CLUBMAXX, Manual

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Torini TC210 CLUBMAXX Manual Download Page 2

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TORINI.COM.AU

ENGINE SAFETY PRECAUTIONS

SERIAL NUMBER LOCATION

APPROVED ENGINE OIL

PRODUCT PARAMETERS

MAINTENANCE STANDARDS

TORQUE VALUES

INTENDED USE

ENGINE SWITCH

MAINTENANCE SCHEDULE

ENGINE OIL

RUN IN PROCEDURE

AIR CLEANER

MUFFLER

SPARK PLUG INSTALLATION/REMOVAL

VALVE CLEARANCE

CARBURETOR

JETTING YOUR CARBURETOR

READING YOUR SPARK PLUG

CLUTCH INSTALLATION/REMOVAL

CLUTCH SETUP

EXHAUST PIPE INSULATION

WET WEATHER AIR FILTER INSTALLATION

LONG TERM STORAGE

TROUBLESHOOTING

LIMITED WARRANTY

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CONTENTS

ENGINE SAFETY PRECAUTIONS

IMPORTANT SAFETY INFORMATION

Most accidents with engines can be prevented if you follow all instructions in this manual and on the engine. Some of the 

most common hazards are discussed below, along with the best way to protect yourself and others.

REFUEL WITH CARE

Petrol is extremely flammable, and gasoline vapor can explode. Refuel outdoors in a well-ventilated area with the engine 

stopped. Never smoke near fuel and keep other flames and sparks away. Always store petrol in an approved container. If 

any fuel is spilled, make sure the area is dry before starting the engine.

CARBON MONOXIDE HAZARD

Exhaust gas contains poisonous carbon monoxide. Avoid inhalation of exhaust gas.

Never run the engine in a closed garage or confined area.

OWNER RESPONSIBILITIES

• The engines are designed to give safe and dependable service if operated according to instructions. Read and understand 

this owner’s manual before operating the engine. Failure to do so could result in personal injury or equipment damage.

• Know how to stop the engine quickly, and understand the operation of all controls.

• Never permit anyone to operate the engine without proper instructions.

• Keep children and pets far away from the area of operation.

• Never modify or change the engine in any way.

HOT EXHAUST

• The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to 

touch the muffler while it is hot. Let the engine cool before storing it indoors.

• To prevent fire hazards and to provide adequate ventilation for stationary equipment applications, keep the engine at 

least 3 feet (1 meter) away from building walls and other equipment during operation. Do not place flammable objects 

close to the engine.

Summary of Contents for TC210 CLUBMAXX

Page 1: ...ALIA NATIONAL HOMOLOGATION 109H This competition engine falls outside the scope of the Product Emissions Standards legislation 2017 and may only be used in competition racing consistent with the requirements of section 9 2 of the PES Rules DESIGNED BUILT IN AUSTRALIA ...

Page 2: ...tore petrol in an approved container If any fuel is spilled make sure the area is dry before starting the engine CARBON MONOXIDE HAZARD Exhaust gas contains poisonous carbon monoxide Avoid inhalation of exhaust gas Never run the engine in a closed garage or confined area OWNER RESPONSIBILITIES The engines are designed to give safe and dependable service if operated according to instructions Read a...

Page 3: ...d when making technical inquiries LOCATION OF SERIAL NUMBER ENGINE MODEL TC210 CLUBMAXX Engine type Single cylinder 4 Stroke Forced Air Cooling OHV25 Bore stroke mm 70 55 Displacement cc 212 Compression ratio 8 5 1 Engine oil capacity L 0 55 Idle speed r min 1800 100 Starting Mode Recoil Lubrication mode Splash Cooling system Forced air cooling Stopping mode Grounding Fuel Premium Unleaded Petrol ...

Page 4: ...sition stops the engine PART ITEM TC210 CLUBMAXX STANDARD SERVICE LIMIT VALVES VALVE CLEARANCE IN EX 0 10 0 02mm 0 15 0 02mm SPARK PLUGS GAP 0 7 0 8mm ITEM TC210 CLUBMAXX Thread dia pitch Tightening torque Nm Cylinder head bolt M8 1 25 32 34 Flywheel bolt M14 1 5 85 90 Valve lock nut M6 0 75 8 10 Valve adjusting bolt M8 1 25 26 32 Crankcase cover bolt M8 1 25 TR160Q TR200Q 8 12 27 30 Magnetic oil ...

Page 5: ...splash lubricated engines It contains enhanced friction modifiers and anti foaming agents blended specifically for Torini race engines Note Do not use Racing Oil prior to run in the friction modifiers will prevent the bed in process from occurring and you will never realise the full power potential of the engine Used engine oil contains carcinogenic substances If repeatedly left in contact with th...

Page 6: ...ini racing oil to run in your engine The friction modifiers will prevent the bed in process from occurring and you will never realise the full power potential of the engine After the first 1 1 5 hours your engine is now fully bedded in replace the run in engine oil with 500ml of the friction modified Torini Racing Oil The oil contains enhanced friction modifiers and anti foaming agents blended spe...

Page 7: ... sealing washer 8 If installing a new spark plug tighten 1 2 turn after the spark plug seats 9 If reinstalling the used spark plug tighten 1 8 1 4 turn after the spark plug seats VALVE CLEARANCE INSPECTION AND ADJUSTMENT MUST BE PERFORMED WITH THE ENGINE COLD 1 Remove the valve cover bolts x 4 valve cover and gasket 2 Set the piston just after TDC on the compression stroke this ensures both valves...

Page 8: ...ut the passage using compressed air and install Reassembly Blow out the passage using compressed air and install Reassembly Blow out the passage using compressed air and install Reassembly Check for worn end of float valve and spring operation before installation Reassembly Check whether it is correctly installed in the groove Reassembly Check for fuel leakage after installation Reassembly Check f...

Page 9: ...C requires that you re jet your carburettor to compensate Going higher results in lower air pressure lower air density When racing at higher elevations your engine is getting less air so it needs less fuel a smaller jet in order to maintain the correct fuel air ratio Under such conditions your horsepower will also go down this is both unavoidable and universal for all competitors you can figure on...

Page 10: ...ll let the engine make good power for a long time without overheating The problem is that a main jet just 1 size too small may make greater power but the engine life will suffer as the operating temperature becomes extreme A slightly rich mixture burns cooler than a lean one so be sure the main jet is big enough MAIN JET SIZES PILOT JET SIZES 90 91 92 93 94 95 96 97 40 43 45 Take out the Idle Spee...

Page 11: ...down immediately after entering the pit lane area do not allow the engine to idle To prevent the crankshaft from turning while attaching or removing the clutch use a long shaft Philips head screwdriver and insert it under the top plate from the crankcase side Slide the tip of the screwdriver through the hole in the crankcase and into the recess of the flywheel as shown below Begin by turning the f...

Page 12: ...hite Spring Engagement Speed 2 700RPM SHOE SETTING OPTIONS Rapid Setting Minor Clutch Slip Moderate Setting Medium Clutch Slip Slow Setting Large Clutch Slip SPROCKET ORIENTATION Having the output or drive sprocket mounted outboard is the preferred orientation for a single engine kart FUNCTION The engine crankshaft is connected to the input of the clutch via a keyed shaft while the output sprocket...

Page 13: ...epending on the brand of chassis the header pipe of the exhaust will vary in distance from the seat We recommend regardless of distance to apply heat insulation to the header pipe in the following manner 2 Fold material into 4 layers Ends to center Then half over 350mm This will do two things Stop heat transfer from the exhaust through your seat adding to driver comfort Stop the potential to accid...

Page 14: ... on the engine for use at a moment s notice Note Ensure hose clamp is done up DO NOT USE IN DUSTY CONDITIONS WARNING The Wet Weather Kit minimises water ingestion by the engine whilst operating in rainy conditions The rear facing air intake uses the karts forward motion to prevent water droplets directly striking the filter intake area while at the same time drawing dry air from one of the most sh...

Page 15: ...ved repairers HARD STARTING ENGINE LACKS POWER POOR PERFORMANCE AT LOW SPEED ENGINE WILL NOT REV SUFFICIENTLY POOR PERFORMANCE AT HIGH SPEED VALVE CLEARANCE INCORRECT SPARK PLUG FOWLED FUEL PUMP VACUUM LINE SPARK PLUG FOWLED IGNITION COIL LOW VOLTAGE STALE OLD FUEL CARBURETOR CONTAMINATION FUEL FILTER CLOGGED CLEAN OR REPLACE REPLACE FUEL RETURN RETURN INSPECT REPLACE INSPECT REPLACE INSPECT REPLA...

Page 16: ...attention is drawn to the following To the extent permitted by law and subject to this Limited Warranty and as part of the terms of the sale of the equipment or part thereof Austech Industries shall not be liable for any form of loss damage cost injury or harm of any kind whether direct indirect special or consequential howsoever arising from the use or supply of the equipment to the purchaser Exc...

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