Carter GTR 250 User Manual
SERVICE MANUAL
INTERCEPTOR GTR 250
This service manual contains the technical data of each component, inspection, and repair,
for the Interceptor GTR 250 and the SANYANG RB1 series engine. The manual is shown
with illustrations and is focused on “Service Procedures”, “Operation Key Points”, and
“Inspection Adjustment”, so that it provides technicians with service guidlines.
If the style and construction of the Interceptor GTR 250 or SANYANG RB1 series engine,
are different from that of the photos, or pictures shown in this manual, the actual vehicle shall
prevail. Specifications are subject to change without notice.
Service Department
drawroF
Carter Brothers Manufactoring, Inc.
How To Use This Manual
This service manual describes basic information of different system parts, system
inspection, and service for the SANYANG RB1 series engine. In addition, please
refer to the manual contents in detail for the model serviced in inspection and
adjustment.
The first chapter covers general information and trouble diagnosis.
The second chapter covers service maintenance information and special tools
manual.
The third to the eleventh chapters cover engine, driving systems and cooling system.
Please see index of contents for quick special parts and system
information.
Contents
xednItnetnoCegaP
1-1 ~ 1-16
2-1 ~ 2-10
3-1 ~ 3-8
4-1 ~ 4-10
5-1 ~ 5-16
6-1 ~ 6-8
7-1 ~ 7-14
8-1 ~ 8-12
General Information
Service Maintenance Information
Lubrication System
Fuel System
Cylinder Head / Valve
Cylinder / Piston
"V" Type Belt Driving System / Kick-Starter
Final Driving Mechanism
1
2
3
4
5
6
7
8
9-1 ~ 9-10
10-1 ~ 10-8
11-1 ~ 11-10
12-1 ~ 12-10
Alternator
Crankshaft / Crankcase
Cooling System
Electrical Equipment
9
10
11
12
Contents
Notes:
Homepage
noitamrofnIlareneG.1
Symbols and Marks····························· 1-1
General Safety ····································· 1-2
Service Precautions ···························· 1-3
Specifications ·····································1-9
Torque Values ·····································1-10
Trouble Diagnosis ····························1-11
Symbols and Marks
Symbols and marks are used in this manual to indicate what and where the special services are needed. In
case supplemental information of procedures are needed for these symbols and marks, explanations will be
added to the text instead of using the symbols or marks.
Warning
Caution
Engine oil
Grease King Mate G-3 is recommended.
Means that serious injury or even death may result if procedures are not
followed.
Means that equipment damages may result if procedures are not followed.
Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the
damage that is caused by not applying the engine oil.
(Recommended oil: KING MATE G-3 oil)
1
King Mate gear oil serials are recommended. (Bramax HYPOID GEAR OIL
Gear oil
Locking sealant
Oil seal
Renew
Brake fluid
Special tools
Correct
Wrong
Indication Indication of components.
Directions
# 140)
Apply sealant; medium strength sealant should be used unless otherwise
specified.
Apply with lubricant.
Replace with a new part before installation.
Use recommended brake fluid DOT3 or WELLRUN brake fluid.
Special tools.
Meaning correct installation.
Meaning wrong installation.
Indicates position and operation directions.
Components assembly are in direction of each other.
Indicates the bolts installation direction, --- means that bolt crosses
through the component (invisibly).
1-1
1. General Information
General Safety
Carbon monoxide
If you must run your engine, ensure the place is
well ventilated. Never run your engine in a closed
area. Run your engine in an open area.If you
have to run your engine in a closed area, be sure
to use an extractor.
Caution
Exhaust contains toxic gas which may cause one
to lose consciousness and even result in death.
Gasoline
Gasoline has a low ignition point and is an explosive
material. Work in a well-ventilated place, no flame
or spark should be allowed in the work place or
where gasoline is being stored.
Caution
Gasoline is highly flammable, and may explode
under some conditions, keep it away from
children.
Used engine oil
Caution
Prolonged contact with used engine oil (or
transmission oil) may cause skin cancer.
it might not be verified.
We recommend that you wash your hands with
soap and water right after contacting. Keep the
used oil beyond reach of children.
Hot components
Caution
Components of the engine and exhaust system
can become extremely hot after engine running.
They remain very hot even after the engine has
been stopped for some time. When performing
service work on these parts, wear insulated
gloves and wait until the component has cooled.
Battery
Caution
Battery emits explosive gases; flame is strictly
prohibited. Keep the place well ventilated
when charging the battery.
Battery contains sulfuric acid (electrolyte)
which can cause serious burns so be careful
Do not get into your eyes or skin. If you
get battery acid on your skin, flush it off
immediately with water. If you get battery acid
in your eyes, flush it immediately with
water and then go to out to see an
ophthalmologist.
If you swallow it by mistake, drink a lot of
water or milk, and go to hospital immediately.
Keep electrolyte beyond reach of children.
Brake shoe
Do not use an air hose or a dry brush to clean
components of the brake system; use a vacuum
cleaner or the equivalent to avoid flying dust.
Caution
Inhaling brake shoe or pad ash may cause
disorders and cancer of the breathing system
Brake fluid
Caution
Spilling brake fluid on painted, plastic, or rubber
parts may cause damage to the parts. Place a
clean towel on the above-mentioned parts for
protection when servicing the brake system.
Keep the brake fluid beyond reach of children.
1-2
Service Precautions
Always use with SANYANG genuine parts and
recommended oils. Using non-designed parts
for Interceptor 250 may damage the kart.
noitamrofnIlareneG.1
Never bend or twist a control cable to prevent
unsmooth control and premature wear.
Special tools are designed for removal and
installation of components without damaging the
parts being worked on. Using wrong tools may
result in damaged parts.
When servicing this kart, use only metric tools.
Metric bolts, nuts, and screws are not
interchangeable with the English system. Using
wrong tools and fasteners may damage this
vehicle.
Clean the outside of the parts or the cover
before removing it from the kart. Otherwise, dirt
and deposit accumulated on the part's surface
may fall into the engine, chassis, or brake
system and cause damage.
Wash and clean parts with high ignition point
solvent, and blow dry with compressed air. Pay
special attention to O-rings or oil seals because
most cleaning agents have an adverse effect on
them.
Rubber parts may become deteriorated when
old, and are prone to be damaged by solvent and oil.
Check these parts before installation to make
sure that they are in good condition, Replace if
necessary.
When loosening a component which has
different sized fasteners, operate with a
diagonal pattern and work from inside out.
Loosen the small fasteners first. If the bigger
ones are loosened first, small fasteners may
receive too much stress.
Store complex components such as
transmission parts in the proper assembly order
and tie them together with a wire for ease of
installation later.
Note the reassemble position of the important
components before disassembling them to
ensure they will be reassembled in correct
dimensions (depth, distance or position).
Components not to be reused should be
replaced when disassembled including gaskets
metal seal rings, O-rings, oil seals, snap rings,
and split pins.
1-3
1. General Information
If the length of bolts and screws for assemblies,
cover plates, or boxes, is different from one
another, be sure they are correctly installed. In
case of confusion, insert the bolt into the hole to
compare its length with other bolts, if its length
outside the hole is the same with other bolts, it
is a correct bolt. Bolts for the same assembly
should have the same length.
Tighten assemblies with different dimension
fasteners as follows: Tighten all the fasteners
with fingers, then tighten the big ones with
special tool, first diagonally from inside toward
outside. Important components should be
tightened 2 to 3 times with appropriate
increments to avoid warp, unless otherwise
indicated. Bolts and fasteners should be kept
clean and dry. Do not apply oil to the threads.
Remove residues of the old gasket or sealant
before reinstallation, grind with a grindstone if
the contact surface has any damage.
The ends of rubber hoses (for fuel, vacuum, or
coolant) should be pushed as far as they can go
to their connections. This is so that there is enough
room below the enlarged ends for tightening the
clamps.
Groove
Clamp
Connector
Rubber and plastic boots should be properly
reinstalled to the original correct positions as
designed.
When oil seal is installed, fill the groove with
grease, install the oil seal with the name of the
manufacturer facing outside, and check the
shaft on which the oil seal is to be installed for
smoothness, and for burrs that may damage the
oil seal.
Manufacturer's name
1-4
Boots
The tool should be pressed against two (inner
and outer) bearing races when removing a ball
bearing. Damage may result if the tool is
pressed against only one race (either inner race
or outer race). In this case, the bearing should
be replaced. To avoid damaging the bearing,
use equal force on both races.
Both of these examples can result in
bearing damage.
1. GENERAL INFORMATION
Lubricate the rotation face with specified
lubricant on the lubrication points before
assembling.
Check to see if positions and operation for installed
parts is in correct and proper.
After service is completed, make sure all
connection points are secured.
Battery positive (+) cable should be connected
first.
the two posts of the battery should be greased
after connecting the cables.
Make sure that the battery post caps are
located properly after the battery posts have
been serviced.
Make sure to use safety when service is being
conducted by two persons. Make sure to use safety when service is
being conducted by two persons.
Caution
Note: Do not let parts fall down.
Before battery removal,
remove the battery negative (-) cable first.
Take steps to avoid an electrical short between
the battery posts.
If the fuse is blown, find the cause and correct it.
Then replace with specified
capacity fuse.
Capacity
verification
1-5
1. General Information
When separating a connector the locker has to
be unlocked first. Then, conduct the service
operation.
Do not pull the wires when removing a connector
or wire. Hold the connector body.
Make sure the connector pins are not bent,
extruded, or loose.
Insert the terminal completely.
Check to see if the terminal is covered by the boot.
Do not let boot open facing up.
Secure wires and wire harnesses to the frame
with respective wire bands at the designated
locations. Tighten the bands so that only the
insulated surfaces contact the wires or wire
harnesses.
Wire band and wire harness have to be
clamped and secured properly.
Insert the connector completely.
If there are two lockers on two connector sides,
make sure the lockers are locked in properly.
Check to see if any wires are loose.
Check to make sure the connector is covered by
the twin connector boot completely, and that it is
secured properly.
Before connecting terminal connection, check to see
if the boot is cracked or the terminal is loose.
Do not squeeze wires against the weld or its
clamp.
1-6
To this chapter contents
1. GENERAL INFORMATION
Do not let the wiring harness come in contact with
rotating, moving, or vibrating components when
routing the harness.
Keep wiring harnesses far away from the hot
parts.
Never Touch
Protect wires or wire harnesses with electrical
tape or tube to protect them from contact with
sharp edges or corners. Throroughly clean the
surface where tape is to be applied.
Secure the rubber boot firmly when applying it on
wiring harness.
Route wiring harnesses to avoid sharp edges or
corners and also avoid the projected ends of
bolts and screws.
Route harnesses so that they neither pull too
tight, nor have excessive slack.
Never too tight
Never use wiring or harnesses if insulation
has been broken. Wrap electrical tape around
the damaged parts or replace them.
Never clamp or squeeze the wiring harness when
installing other components.
Never clamp or
squeeze the wiring
harness.
1-7
1. General Information
To this chapter contents
Do not let the wiring harness get twisted during
installation.
Wiring harnesses routed along the framebar
should not be pulled too tight, have excessive
slack, be rubbed against, or interfere with
adjacent or surrounding parts in all steering
positions.
Use sand paper to clean rust on connector
pins/terminals if found. Then conduct
connection operation.
Clean rust
Before operating a test instrument, operator
should read the operation manual of the
instrument. Then, conduct test in
accordance with the instruction.
Do you know how to set the
instrument to its
measurement position and then
insert the two probes in the
specific location.
1-8
Specifications
Cylinder
1. GENERAL INFORMATION
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1-9
1. General Information
Torque Values
The torque values listed in the following table are important torque values. Please use standard
values for bolts not listed in the table.
Standard Torque Values for Reference
Type Tighten Torque Type Tighten Torque
5 mm bolt nut
6 mm bolt nut
8 mm bolt nut
10 mm bolt nut
12 mm bolt nut
Engine Torque Values
Item Q’ty Thread Dia. (mm) Torque Value(kgf-m) Remarks
Cylinder stud bolt 4 10 1.0~1.4
Cylinder head nut 4 8 3.6~4.0
Cylinder head right bolt 2 8 2.0~2.4
Cylinder head side cover bolt 2 6 1.0~1.4
Cylinder head cover bolt 4 6 1.0~1.4
Cylinder head stud bolt (inlet pipe) 2 6 1.0~1.4
Cylinder head stud bolt (EX. pipe) 2 8 2.4~3.0
Air inject pipe bolt 4 6 1.0~1.4
Air inject reed valve bolt 2 3 0.07~0.09
Tappet adjustment screw nut 4 5 0.7~1.1 Apply oil to thread
Tensioner lifter bolt 2 6 1.0~1.4
Carburetor insulator bolt 2 6 0.7~1.1
Oil pump screw 2 3 0.1~0.3
Water pump impeller 1 7 1.0~1.4
Engine left cover bolt 9 6 1.1~1.5
Engine oil draining bolt 1 12 3.5~4.5
Engine oil strainer cap 1 30 1.3~1.7
Mission draining bolt 1 8 1.1~1.5
Mission filling bolt 1 12 3.5~4.5
Shift drum fixing bolt 1 14 3.5~4.5
Clutch driving plate nut 1 28 5.0~6.0
Clutch outer nut 1 14 5.0~6.0
ACG. Flywheel nut 1 14 5.0~6.0
Crankcase bolts 7 6 0.8~1.2
Mission case bolt 7 8 2.6~3.0
Exhaust muffler connection nut 2 8 1.0~1.4
Engine hanger nut 4 12 8.0~9.0
0.45~0.6kgf-m 5 mm screw 0.35~0.5kgf-m
0.8~1.2kgf-m
1.8~2.5kgf-m
3.0~4.0kgf-m
5.0~6.0kgf-m
6 mm screw SH nut
6 mm bolt nut
8 mm bolt nut
10 mm bolt nut
0.7~ 1.1kgf-m
1.0 ~1.4kgf-m
2.4 ~3.0kgf-m
3.5~4.5kgf-m
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1-10
1. GENERAL INFORMATION
g
Trouble Diagnosis
A. Engine hard to start or can not be started
Check and adjustment Fault condition Probable causes
Loosen carburetor drain bolt to
check if there is gasoline inside
the carburetor.
Fuel supplied tom
carburetor sufficient.
Remove spark plug, install it
into spark plug cap, and perform
a spark test against engine
round.
Check if sparks. Weak sparks, no spark at
Perform cylinder compression
pressure test.
No fuel is supplied to
carburetor.
all.
No fuel in fuel tank.
Check if the pipes, fuel tank to carburetor
and intake vacuum, are clogged.
Float valve clogged.
Lines in fuel tank evaporation system
clogged.
Malfunction of fuel pump.
Loosen or damaged fuel pump vacuum
hose.
Fuel filter clogged.
Malfunction of spark plug.
Spark plug foul.
Malfunction of CDI set.
Malfunction of AC generator.
Ignition coil is in open or short circuit.
Ignition coil leads open or short circuit .
Malfunction of main switch.
Cylinder compression
pressure normal.
Re-start by following the starting
procedures.
No ignition. There are some signs of
Remove the spark plug again
and check it.
Dry spark plug. Wet spark plug.
Remove carburetor after 30
minutes and connect a hose
onto fuel rich circuit. Then blow
the hose with air.
Low compression
pressure or no pressure.
ignition;But engine can
Piston ring seized.
Malfunction of cylinder valves.
Worn cylinder and piston ring.
Cylinder gasket leak.
Sand hole in compression parts.
Malfunction of throttle valve operation.
Air sucked into intake manifold.
Incorrect ignition timing.
Fuel level in carburetor too high.
Malfunction of throttle valve operation.
Throttle valve opening too wide.
Blowing in normal. Blowing clogged.
Malfunction of automatic by- starter.
1-11
1. General Information
B. Engine runs sluggish (Speed does not pick up, lack of power.
Check and adjustment Fault condition Probable causes
Try gradual acceleration and
check engine speed.
Air cleaner clogged.
Engine speed can be
increased.
Check ignition timing (Using
ignition lamp).
Engine speed can not be
increased.
Poor fuel supply.
Lines in fuel tank evaporation system
clogged.
Exhaust pipe clogged.
Fuel nozzle clogged in carburetor.
Fuel nozzle clogged in carburetor.
Ignition timing correct. Incorrect ignition timing.
Check cylinder compression
pressure using compression pressure
gauge.
Compression pressure
correct.
Check if carburetor jet is
clogged.
Not clogged. Clogged.
Remove spark plug.
No foul or discoloration. Fouled and discoloration.
No compression pressure.
Malfunction of CDI.
Malfunction of AC alternator.
Cylinder and piston ring worn out.
Cylinder gasket leaked.
Sand hole in compression parts.
Valve deterioration.
Seized piston ring.
Remove foreign material.
Remove dirt.
Incorrect spark plug heat range.
Check if engine overheated.
Normal. Engine overheated.
Continually drive in acceleration
or high speed.
No knock. Knock.
1-12
Piston and cylinder worn out.
Lean mixture.
Poor fuel quality.
Too much carbon deposited in
combustion chamber.
Ignition timing too advanced.
Poor circuit on the cooling system.
Too much carbon deposited in
combustion chamber.
Lean mixture.
Poor fuel quality.
Ignition timing too advanced.
1. GENERAL INFORMATION
C. Engine runs sluggish (especially in low speed and idling)
Check and adjustment Fault condition Probable causes
Check ignition timing (using
ignition lamp).
Normal.
Adjust the air screw of
carburetor.
Good. Poor.
Air sucked through carburetor
gasket.
No air sucked. Air sucked.
Remove spark plug, install
spark plug into spark plug cap
and perform spark test against
engine ground.
Good spark. Poor.
Abnormal.
D. Engine runs sluggish (High speed)
Incorrect ignition timing (malfunction of
CDI or AC alternator).
Rich mixture (loosen the screw).
Lean mixture (tighten the screw).
Poor heat insulation gasket .
Carburetor lock loose.
Poor intake gasket.
Poor carburetor O-ring.
Vacuum hose crack.
Spark plug fouled.
Malfunction of CDI.
Malfunction of AC generator.
Malfunction of ignition coil.
Open or short circuit in spark plug leads.
Malfunction of main switch.
Check and adjustment Fault condition
Check ignition timing.
Normal. Abnormal.
Check for fuel supplying system
in automatic fuel cup.
Good. Abnormal.
Check if carburetor clogged.
Not clogged. Clogged.
Probable causes
Malfunction of CDI.
Malfunction of AC alternator.
Insufficient fuel in fuel tank.
Fuel filter clogged.
Restricted fuel tank vent.
Cleaning.
1-13
1. General Information
E. Clutch, driving and driving pulley
FAULT CONDITIONS
Engine can be started but
kart can not be moved.
Engine running and misfire as kart
initailly moves forward or jumps
suddenly (rear wheel rotating as
engine is running).
Poor initial driving (Poor climbing
performance).
PROBABLE CAUSES
Drive belt worn out or deformed.
Ramp plate of movable drive face damaged.
Driving pulley spring broken.
Clutch weights broken.
Drive slide-shaft gear groove broken.
Transmission gear damaged.
Clutch weights spring broken.
Clutch outer stuck with clutch weights.
Connection parts in clutch and shaft worn out or burned.
Drive belt worn out or deformed.
Weight roller worn out.
Movable drive face shaft worn out.
Driven pulley spring deformed.
Driven pulley shaft worn out.
Grease in drive belt or driven face.
1-14
1. GENERAL INFORMATION
F. Loss of power
Check and adjustment Fault condition Probable causes
Raise wheels off ground and
spin by hand.
Brake dragging.
Spin freely.
Check tire pressure.
Abnormal.
Drive chain too tight.
Damaged wheel bearing.
Wheel bearing needs lubrication.
Normal. Abnormal.
Accelerate lightly, engine speed
can be increase.
Normal. Abnormal.
Check ignition timing.
Normal. Abnormal.
Test cylinder compression.
Normal. Abnormal.
Check carburetor.
Normal. Clogged.
Punctured tire.
Faulty tire valve.
Fuel / air mixture ratio too rich or lean.
Clogged in air cleaner.
Clogged in muffler.
Restricted fuel flow.
Clogged fuel tank cap breather hole.
Faulty pulse generator.
Faulty CDI unit.
Leaking head gasket.
Worn cylinder and piston rings.
Clean.
Check spark plug.
Normal. Fouled or discolored.
Check for engine overheating.
Normal. Overheating.
Accelerate or run at high speed
Normal. Knocks.
Clean the spark plug.
Spark plug has incorrect heat range.
Excessive carbon deposited in
combustion chamber.
Wrong type of fuel.
Fuel / air mixture ratio is lean.
Use of poor quality fuel.
Worn piston and cylinder.
Fuel / air mixture ratio is lean.
Wrong type of fuel.
Ignition timing too advanced.
Excessive carbon deposited in
combustion chamber.
1-15
1. General Information
Notes:
1-16
2. Maintenance Information
Precautions in Operation ···················· 2-1
Periodical Maintenance Schedule ·····
Air Cleaner...........................................
Spark Plug ·········································· 2-3
Valve Clearance ··································
Carburetor Idle Speed Adjustment····· 2-4
Ignition System ····································
Precautions in Operation
Specification
2-2
2-2
2-3
2-5
Cylinder Compression Pressure ·······
Drive Belt ·············································· 2-6
Wheel/Tire············································· 2-6
Nut, Bolt Tightness ······························2-6
Brake System (Disk Brake) ················
Drive Chain ·········································· 2-8
Gear Shift Lever ··································
Special Tools List ···············2-10 thru 2-12
2-5
2-7
2-9
2
Engine Oil
Transmission Gear oil
Spark plug
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2-1
2. Maintenance Information
Periodical Maintenance Schedule
Maintenance
Code
1 Air cleaner
2 Fuel filter
3 Oil filter
4 Engine oil change
5 Every screw tightening check
6 Gear oil check for leaking
7 Spark plug check or change
8 Gear oil change
9 Ignition timing
10 Emission check in idling
11 Engine bolt tightening
12 CVT driving device(belt)
13 CVT driving device(roller)
14 Cam chain
15 Valve clearance
16
17 Coolant reservoir
18 Coolant
Lines & connections in cooling
Item
Every
300KM
IC R
IIR
CC
R Replacement for every 1000 km
II
II
IIR
R Replacement for every 5000 km
II
AI
II
II
IA
II
II
II R
1 month
every
1,000KM
3 months
every
3,000KM
6 months
every
6000KM
IR
C
1 year
every
12,000KM
15 months
every
14,500KM
Code: I ~ Inspection, cleaning, and adjustment R ~ Replacement
C ~ Cleaning (replaced if necessary) L ~ Lubrication
Have your kart checked and adjusted by an authorized Carter Dealer in accordance with the Periodical Maintenance
Schedule (please see above table).
The above maintenance schedule is established by taking the monthly 1000 kilometers as a reference, which ever
comes first.
Remarks: 1. Clean or replace the air cleaner element more often when the kart is operated on dusty roads or in
an heavily- polluted environment.
2. Maintenance should be performed more often if the kart is frequently operated at high speeds and
after the kart has accumulated a higher mileage.
3. Preventive maintenance.
a. Ignition system
Perform maintenance and check when continuous abnormal ignition, misfire,
after-burn, or overheating occur.
b. Carbon deposit removal
Remove carbon deposits in cylinder head, piston heads, and exhaust system
when power is obviously lower.
Air Cleaner
Remove seat.
loosen 4 hooks from the air cleaner cover and
then remove the cover.
Loosen the clamp strip and 1 screw of air cleaner
element, and then remove the air cleaner element.
Clean the element with non-flammable or
high-flash point solvent and then squeeze it for
dry.
Clamp
Element
Caution
Never use gasoline or acid organized solvent to
clean the element.
Soap the element into cleaning engine oil and then
squeeze it out. Install the element onto the
element seat and then install the air cleaner cover.
2-2
2. Maintenance Information
Spark Plug
Recommended spark plug: CR8E
Remove spark plug cap.
Clean dirt around the spark plug hole.
Remove spark plug.
Measure spark plug gap.
Spark plug gap
Carefully bend ground electrode of the plug to
adjust the gap if necessary.
Hold spark plug washer and install the spark plug
by screwing it.
Tighten the plug by turning 1/2 turn more with plug
socket after installed.
Tighten torque: 1.0
0.8 mm
~1.2kgf-m
Valve Clearance
Caution
Checks and adjustment must be performed when
the engine temperature is below 35
Remove , fuel tank cover, and fuel tank.
Remove cylinder head cover.
Remove cylinder head side cover.
Turn camshaft bolt in C.W. direction and let the “T”
mark on the camshaft sprocket align with cylinder
head mark so that the piston is placed at TDC position
in compression stroke.
.
Ground electrode
Central electrode
0.8~0.9mm
Timing mark
2 bolts
Caution
Do not turn the bolt in C.C.W. direction to prevent
camshaft bolt looseness.
Perform valve clearance inspection and adjustment.
Check & adjust valve clearance with feeler gauge.
Standard Value: IN 0.10 ± 0.02 mm
EX 0.15 ± 0.02 mm
Loosen fixing nut and turn the adjustment nut for
adjustment.
Caution
Re-check the valve clearance after tightening the
fixing nut.
2-3
To this chapter contents
2. Maintenance Information
Carburetor Idle Speed Adjustment
Caution
Inspection & adjustment for idle speed must
be performed after all parts in engine that
needed adjustment have been adjusted.
Idle speed check and adjustment have to be
done after engine is warmed up.
Park the kart, put in neutral, set the parking brake
and warm up the engine.
Connect tachometer (the wire clamp of tachometer
is connected to the high tension cable).
Turn the throttle valve stopper screw to specified
idle speed.
Specified idle speed: 1700 ± 100 rpm
Stopper screw
Emission adjustment in idle speed
Warm up the engine for about 10 minutes and
then conduct adjustment.
1. Connect the tachometer onto engine.
2. Adjust the throttle valve stopper screw and let
engine run in 1600±100 rpm.
3. Insert the exhaust sampling pipe of exhaust
analyzer into the front section of exhaust pipe.
Adjust the air adjustment screw so that
emission value in idle speed is within standard.
4. Slightly accelerate the throttle valve and
release it immediately. Repeat this for 2~3
times.
5. Read engine RPM and value on the exhaust
analyzer. Repeat step 2 to step 4 procedures
until measured value within standard.
Emission standard CO: below 2.5~3.5%
HC: below 2000ppm
Air adjustment screw
2-4
Ignition System
Caution
C.D.I ignition system is set by manufacturer so
it can not be adjusted.
Ignition timing check procedure is for checking
whether CDI function in normal or not.
Connect tachometer and ignition light.
Start engine.
As engine is in idle speed: 1600 rpm, aim at the
mark “F” with the ignition light. Then, it means
that ignition timing is correct.
Increase engine speed to 6000 rpm to check
ignition advance degree. If indent is located within
the ignition advance degrees, it means that the
ignition advance degree is normal.
If ignition timing is incorrect, check CDI set, pulse
rotor and pulse generator. Replace if
malfunction of these parts is found.
2. Maintenance Information
Cylinder Compression Pressure
Warm up engine.
Turn off the engine.
Remove the trunk.
Remove the central cover.
Remove spark plug cap and spark plug.
Install compression gauge.
Fully open the throttle valve, and rotate the engine
by means of starter motor.
Caution
Rotate the engine until the reading in the gauge
is increasing no more.
Usually, the highest pressure reading will be
obtained in 4~7 seconds.
Compression pressure: 12 ± 2 Kg/cm²
Check following items if the pressure is too low:
Incorrect valve clearance.
Valve leaking.
Cylinder head leaking, piston, piston ring and
cylinder worn out.
If the pressure is too high, it means carbon
deposits in combustion chamber or piston head.
2-5
To this chapter contents
2. Maintenance Information
Drive Belt
Loosen the 2 clamp strips of left crankcase cover,
and then remove the left crankcase cover vapor
hose.
Remove 9 bolts of the engines left side cover and
the cover.
Check to see if the belt is cracked or worn out.
Replace the belt if necessary or in accordance with
the Periodic Maintenance Schedule.
Width limit: 22.5 mm or above
Clamp strips
9 bolts
Teeth
Width
Wheel/Tire
Caution
Tire pressure check should be done as cold
engine.
Front Tire 23x7-10 14psi
Rear Tire 25x10-12 14psi
Nuts, Bolts Tightness
Perform periodic maintenance in accord with the
Periodic Maintenance Schedule
Check if all bolts and nuts on the frame are
tightened securely.
Check all fixing pins, snap rings, hose clamp, and
wire holders for security.
2-6
Brake System (Disk Brake)
Brake System Hose
Check the brake hoses for corrosion or
leaking oil.
Brake Fluid
Check brake fluid level in the brake fluid
reservoir. If the level is lower than the LOWER
limit, add brake fluid to UPPER limit. Also check
brake system for leaking if low brake level found
Caution
Do not operate the brake pedal while the cap is
removed. Otherwise, the brake fluid
will spill.
Do not mix non-compatible brake fluid together.
2. MAINTENANCE INFORMATION
Filling Out Brake Fluid
Tighten the drain valve, and add brake fluid.
Operate the brake pedal so that brake fluid
will build pressure.
Air Bleed Operation
Connect a transparent hose to the draining valve.
Hold the brake pedal and open air bleeding valve.
Repeat this operation until there is no
air inside the brake system hoses.
Caution
Close the air bleed valve. Before releasing
the brake pedal.
Adding Brake Fluid
Add brake fluid to UPPER limit lever.
Recommended brake fluid: DOT3 or DOT4
Caution
Never mix or use dirty brake fluid to prevent
damage to brake system or reducing brake
performance.
Air bubble
Drain valve
Transparent hose
2-7
2. MAINTENANCE INFORMATION
Brake Lining Wear
The indent mark on brake lining is the wear
limitation.
Replace the brake lining if the wear limit mark is
close to the edge of the brake disc.
Caution
Front brake
Lining
To check the front brake lining, you must
remove the front wheel first.
It is not necessary to remove brake hose when
replacing the brake lining.
How to Tighten Chain:
a. On this unit, to tighten the chain the entire
engine must be “slid” forward.
b. Loosen the engine plate bolts (2 front and 2 rear).
c. Loosen air box bolts (4 total).
d. Loosen muffler bolts (2 total).
e. Slide engine forward and tighten all bolts.
NOTE: When pushing the engine forward the
front engine mount will try and tilt forward. This will
cause the engine to return to its original position
once force is removed. You will need to tap the
bottomof the engine plate to keep it from tilting.
Check gear positions after adjusting chain.
Brake lining wear
limitation groove
Brake disk
REAR PLATE BOLTS
FRONT PLATE BOLTS
AIR BOX BOLTS
How to Lubricate Chain:
Lubricate chain with a spray-on type chain lubricant
to increase the life of the chain.
2-8
MUFFLER BOLTS
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