Swissauto 250 Assembly Instructions And Operating Manual

31

! IMPORTANT NOTICE!

This engine is designed strictly for competition purposes only.

The manufacturer SWISSAUTO declare that all spare parts and

engines are not covered by any warranty.

Only SWISSAUTO can recognize the manufactured defect after

control.

The authoritative manual

in case of discrepancy is the

manual on the website

www.swissauto.com

swissaut

o

swissaut

o

swissaut

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swissaut

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EVO2

Assembly Instructions

and

Operating Manual

1

Contents

All indications and procedures described in this manual are up to date at the time
of publication and have been defined to the best of one’s knowledge, however
excluding any liability.

All rights reserved. Subject to technical modification. Errors expected.
Reproduction, translation or distribution of this publication, even in extracts, only
with prior written permission of:

2 Scope of Supply

3 Installation onto the Go-Kart

14 Start-up

16 Maintenance

18 Special Tools

19 Recommended Accessories

20 Tips and Tricks

21 Dismantling the Clutch

23 Assembling the Clutch

24 Wiring Plan

25 Basic Settings of the Carburetor

26 Table Main Jets

27 Table Gear Ratios

28 Table Tightening Torque

29 Technical Data

30

Buchmattstrasse 46 - 48

3400 Burgdorf

Schweiz

www.swissauto.com

Customer’s name

Engine number

Your official dealer

29

Technical Data

Engine 1 cylinder 4 stroke with balance shaft

Cooling

Water cooled, water pump in engine block
integrated

Engine casing Gravity die cast Aluminium

Cylinder Gravity die cast Aluminium with Nicasil coating

Bore / Stroke 75 / 56.5 mm

Displacement 249.6 ccm

Power

35 / 39 HP at 10'000 1/min with 30 / 34 mm
carburetor

Cylinder head 4 valves per cylinder, DOHC on roller bearings

Crankshaft Steel, forged, roller bearings

Piston Aluminium forged

Connecting rod Steel, forged, mounted on roller bearings

Lubricating system Integrated dry sump with diaphragm pump

Ignition Digital battery ignition with rpm limiter

Carburetor Dell'Orto D = 30 mm / 34 mm

Fuel pump Vacuum pump integrated into the engine casing

Transmission

Gearless drive with centrifugal clutch and chain
drive

Dimensions L/W/H = 410/190/330 mm

Weight 15 kg incl. starter

Spark plug gap 0.6 mm
Distance generator

stator

1.2 mm to magnets

2

Scope of Supply

● engine ‚swissauto 250’ with clutch, ignition and fuel pump

● radiator

● radiator support with silent blocks, bolts and nuts

● 2 cooler hoses

● 3 hose clamps 27.1

● 1 hose clamp 28.6

● carburetor

● carburetor rubber

● 2 hose clamps for carburetor rubber

● air filter flange

● air filter incl. clamp

● crankcase ventilation hose with ventilation tube 90°

● ignition coil with spark plug boot

● battery box with battery, relay and cabling

● control unit

● 3 pipe clamps with bolts and nuts

● primary tube with gasket and nuts

● exhaust silencer

● 2 silencer springs

● throttle cable (inner wire and sleeve)

● clamp for throttle cable

3

Installation onto the Go-Kart

Step 1: Complete the engine by assembling the ignition coil, the radiator

and the carburetor. Charge the battery!

Mount the ignition coil as shown
on the cylinder head.

Use the screw M6x40 with
washer and tighten with 10Nm.

Insert the spark plug boot into
the plug hole and push it onto
the spark plug.

28

Table Tightening Torque

Tightening Torque Thread Strenght Nm

Engine mount allen screw

Loctite

243 M8 8.8 22

Transmission sprocket bolt hexagon
with flange M6 8.8 13

Transmission sprocket nut hexagon M28x1 110

Clutch mount nut heaxagon M24x2 150

Spark plug A/F 16 M10x1 12

Generator-stator (coil) M6 8.8 10

Mounting bolt for oil filter hexagon M14x1.5 26

Oil drain plug hexagon (magnetic) M14x1.5 26

CLUTCH:

Starter sprocket with clutch mount
hexagon M 8 10.9 22

Starter sprocket with clutch mount
hexagon M 7 8.8 22

Starter sprocket with support ring allen
screw

M 6

stainless

steel 10

27

Table Gear Ratios

Top Speed at 13'000 rpm

Transmission

sprocket

Rear

sprocket Top Speed [km/h]

Transmission

sprocket

Rear

sprocket Top Speed [km/h]

11 90 83.9 14 88 109.2

11 89 84.8 13 81 110.2

11 88 85.8 14 87 110.5

11 87 86.8 13 80 111.5

11 86 87.8 14 86 111.7

11 85 88.8 13 79 113.0

11 84 89.9 14 85 113.1

11 83 91.0 13 78 114.4

11 82 92.1 14 84 114.4

11 81 93.2 14 83 115.8

11 80 94.4 13 77 115.9

11 79 95.6 14 82 117.2

11 78 96.8 13 76 117.4

11 77 98.1 14 81 118.6

13 90 99.1 13 75 119.0

11 76 99.3 14 80 120.1

13 89 100.3 13 74 120.6

11 75 100.7 14 79 121.6

13 88 101.4 13 73 122.2

11 74 102.0 14 78 123.2

13 87 102.6 13 72 123.9

11 73 103.4 14 77 124.8

13 86 103.8 13 71 125.7

11 72 104.9 14 76 126.4

13 85 105.0 13 70 127.5

13 84 106.2 14 75 128.1

11 71 106.3 14 74 129.9

14 90 106.8 14 73 131.6

13 83 107.5 14 72 133.5

11 70 107.9 14 71 135.3

14 89 108.0 14 70 137.3

13 82 108.8

4

Installation onto the Go-Kart

Bolt M8x80 with washer

Self-locking flange nut M8

Tighten with 12Nm.

2x flange nuts M6

Silent block 20x10 M6x12/12

Tighten with 10Nm.

Avoid distortion of the silent block during
installation of cooler hose up.
Otherwise shorten the cooler hose
accordingly.

Radiator support

Bolt M6x16 with washer
Tighten with 10Nm.