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International Karting Industry Buyer's Guide

Kart Expo International
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FUN KART MAINTENANCE
Fun karts come in all shapes and sizes. However, maintenance for every kart is nearly identical. The following are basic maintenance tips for your fun kart. Follow them and you’re kart will last longer and should be safer for you to operate.

Two critical things for you to remember to maintain your kart engine is basic to any 4-cycle engine, even in your automobile: Keep the air filter clean and the oil changed at proper intervals.

AIR FILTER
The air filter or air cleaner will accumulate dust and should be replaced after every 100 operating hours. If riding in dusty areas, the filter will need to be replaced more frequently. A dirty air filter will cause your kart to run poorly.

To inspect filter:
1. Remove wing nut and cover. Remove the element.
2. Inspect element for condition
3. Replace filter if needed. Filters can be purchased at any authorized engine dealer.

ENGINE OIL
The suggested engine oil type is SAE 30.
Check engine oil after every 5 operating hours and before each use.
Oil level should be between the full and add marks on the dipstick.
Change engine oil after the first 2 hours of use and then after every 25 hours of use.

ENGINE
Refer to operators manual and maintenance instructions for full service instructions

SPARK PLUG
The spark plug is located on top of the kart engine.
Standard spark plug for the Tecumseh engine is Champion RN4C only or equivalent.

To inspect spark plug do the following:
1. Disconnect the spark plug cap.
2. Clean dirt/debris from around the spark plug base.
3. Remove the spark plug by using the spark plug wrench or proper socket.
4. Replace spark plug if electrodes are pitted, burned, fouled with deposits, or porcelain is cracked.
5. Check electrode gap with wire feeler gauge and set gap at .030 or per operating instructions.
6. Install spark plug, tighten snugly, but do not over tighten.

FUEL
Fresh, clean, regular unleaded gasoline.
Filling instructions:
a. Clean area around fuel cap.
b. Add “unleaded” regular gasoline, slowly to the gas tank. Use a funnel to avoid spilling.
c. Install fuel cap and wipe up any spilled gasoline.

Fuel Safety Tips
1. Never fill fuel tank indoors.
2. Never fill fuel tank while engine is running or hot.
3. Do not smoke while filling fuel tank.
4. Never fill fuel tank completely. Fill tank to ½” below bottom of neck to provide space for fuel expansion.
5. Wipe any fuel spillage from engine and equipment before starting engine.
6. Store fuel in a safe area and in a proper container.

DRIVE TRAIN ASSEMBLY

CHAIN TIGHTENING
The drive chain will wear with use and requires periodic adjustment. Chain slack is measured by pushing down on chain between the two sprockets. The amount of slack should be 3/8”-1/2”. To tighten chain, loosen the four bolts on the bottom of the engine and pull the engine backwards.

CHAIN LUBRICATION
For longer chain life, lubrication is required before each ride. This can be accomplished by using a non-oil based graphite spray. Do not use oil or grease on the chain. Oil and grease attract dirt and dust, which will shorten the life of the chain.

CENTRIFUGAL CLUTCH LUBRICATION
The centrifugal clutch will provide many hours of use if maintained properly. Cleaning and lubrication is necessary for long life and trouble free operation. The clutch bearing should be lubricated after every 2 hours of operation. Do not lubricate inside of the clutch drum.

Centrifugal clutch maintenance:
a. Remove the drive unit cover.
b. Clean all dust and dirt residue from all surfaces.
c. Lubricate clutch with SAE 30 oil. This is accomplished by placing oil around the base of the clutch while turning the wheel to work the oil into the clutch bearing.
d. Reassemble drive unit cover making sure it is securely in place.

TORQUE CONVERTER
The torque converter will provide many hours of use if maintained properly. Periodic cleaning and lubrication is necessary for long life and trouble free operation.

Torque Converter maintenance:
a. Remove the drive unit cover.
b. Pull the torque converter off of the drive shaft.
c. Clean all dust, dirt and belt residue from all surfaces using an evaporative solvent.
d. Re-lubricate all parts of torque converter with a dry lubricant such as a non-oil based graphite spray. NOTE: Do not get any lubricant on the face plates which come in contact with belt.
e. Reassemble drive unit cover making sure it is securely in place.

THROTTLE CABLE AND BRAKE CABLES
Inspect throttle and brake cable condition and operation. Replace cable if it has become worn or kinked. Lubricate cable with cable lubricant to prevent premature wear or corrosion. Make sure spring, rod and fasteners are in good condition.

CHASSIS LUBRICATION
After every 3 hours of use, lubricate the following items with a few of drops of SAE 30 oil.
a. All steering pivot points
b. Steering spindles
c. Steering tie rod pivot points
d. Pedal pivot points

One last point, when riding a fun kart, be sure wear a helmet, and don’t have any long hair or scarves or the like hanging from the driver. Above all, be safe and have fun!

END

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Kart Marketing Group, Inc.
Post Office Box 101
Wheaton, IL 60189 USA
Telephone: 630-653-7368
Fax: 630-653-2637
Email: karting@msn.com

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