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SPARK PLUG INSTALLATION/REMOVAL

MUFFLER

VALVE CLEARANCE

APPROVED TYPE: BPR6ES (NGK)

*** Always use BPR6ES Spark Plugs as per KA Homologation. ***

1) Remove the spark plug cap.

2) Remove the spark plug with a spark plug wrench.

3) Visually inspect whether the insulator is cracked or chipped, if so, replace it with

a new one, if there are excessive deposits on it; clean it with a wire brush.

4) Measure the electrode gap with a feeler gauge. The correct gap is 0.70-0.80mm

(0.028 - 031 in). If necessary, adjust the gap by carefully tapping (for a too big

gap) the electrode or gently forcing up (for a too small gap) the electrode using

a slotted screwdriver.

5) Make sure the spark plug’s sealing washer is in good condition.

6) Install the spark plug and use a spark plug wrench to tighten it into the cylinder

head.

7) When installing the spark plug, in order to prevent cross-threading, first use

hand to screw it in the direction as shown by the arrow to install it into the

tapped hole in the cylinder head, then tighten with a plug wrench to compress

the 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 are fully closed and the automatic

decompressor is not interfering with setting the valve clearances.

3) Insert a feeler gauge between the rocker arm and valve to measure valve clearance.

4) If adjustment is necessary, proceed as follows:

a. Hold the rocker arm pivot with a wrench and loosen the pivot lock nut.

b. Loosen the rocker arm pivot and turn the rocker arm pivot to obtain the specified valve clearance.

c. Hold the rocker pivot with a wrench and tighten the lock nut 8 –10 Nm only.

d. Rotate the engine a few times and recheck the valve clearance after tightening the lock nut.

0.70-0.80 mm

VALVE

CLEARANCE

0.10±0.02mm

(0.004±0.001”)

0.15±0.02mm

(0.006±0.001”)

• When running the muffler will heat

up, please make inaccessible to

passers-by and children.

• Never put any flammable material

near the exhaust port.

WARNING

DANGER

WARNING HOT SURFACE

Содержание TC210 CLUBMAXX

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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