Formula TKM 4-Stroke Installation Guide 2012 - Tal-Ko

FORMULA TKM 4-STROKEInstallation GuideIntroductionThis installation guide is provided for ownerswho are fitting a TKM 4-stroke engine to theirown kart and should be read carefully beforeinstallation begins. The engine package isprovided to you in a form which is easy to fit toyour kart and should take less than an hour withminimal needs. Please follow this guidecarefully.Step 1Engine comes complete with:- Radiator,Carburettor, Noise box, Exhaust, Engine Mount(less clamps), 1 Litre of Oil and the Oil BreatherCondenser Pot together with the Petrol PulsePump mounted on the seat bracket with pipes.The standard mounts are available in either 90x 32 or 92 x 32. They are stamped with 90 or92 on the bottom face in a recess foridentification. Other sizes of mounts areavailable to special order.Step 2Place the engine onto the chassis and ensurethat the engine mounts fit correctly. Make surethat the engine is clear of seat brackets and canslide along the chassis rails a small distance toallow for chain adjustment. We can supply youwith a set of 2 rising blocks with 4 longer bolts toraise engine by 9mm to give extra clearance onside bar mounting if required. Fit mount clampsand secure lightly with mounting bolts. Ensurethat the mounting bolts are the correct lengthand neither too long so that they bottom or tooshort so that there is insufficient thread holding.Step 3Take the bracket with condenser pot and pulsepump mounted and locate on the rear of theseat. This should be mounted as high aspossible on the seat so that the top of thecondenser unit is at least 30mm above the seatlip. The pot must also be as close as possible tovertical. It should be fitted to the rear of the seatbut to the right hand side of the centre point sothat it is close to the engine. Drill the seat andmount using the bolts and spacers provided.When bolting up note that there is 10 degrees ofrotational adjustment available in the M5 slottedholes of the condenser pot mount on thebracket. This makes it easy to gain the bestposition for the main large breather pipe fromthe engine.Step 4Connecting the oil breathing pipes. The smallclear oil return pipe should be connected fromthe engine to the small union at the bottom ofthe pot ensuring that there is a nice smoothsteady fall on the pipe from condenser to engine.Trim if required and cable tie. Without thissteady fall oil will collect in pipe and restrict oilreturning to engine.The larger pipe should run straight up from theengine and then naturally over the top of thecarb inlet manifold and across to the condenserpot union with a steady rise if possible. Againtrim if required. Secure with a cable tie – thoughnote this is the pipe you will have to remove toinsert oil into the engine.Step 5Connect the fuel system piping. But firstremember that if you have previously been usingthe fuel tank with a two-stroke engine you MUSTempty the tank and flush with clean unmixed fuelin a safe environment. Also note that this enginerequires an extra outlet/inlet on the tank (three intotal) so this should be fitted in the top of thetank at this stage. Make sure the tank is cleanand flushed after drilling and fitting of extraunion. An inline tank filter is highlyrecommended.Pipe 1(Fuel Supply) is connected from the tankpick-up connector to the in arrow union on thepulse pump.Pipe 2 (Fuel Supply) goes from the pulse pumpout arrow union to one end of the Y connector(not fitted with the 70 fuel return jet).Pipe 3 (Fuel Supply) goes from the long end ofthe Y connector to the carburettor in union.1

Pipe 4 (Fuel Return) goes from the remainingshort end of the Y connector (with 70 jet) to thenew fuel tank union. This is the fuel return pipe.Pipe 5 (Breather Pipe) goes from the tank to actas a breather – ideally located into a highmounted catch tank. The Y connector should belocated as high as possible on the kart justbetween the engine and the condenser potbracket. The Y connector arm with return jetinserted should be highest of all. This helps toremove trapped air from the pipes. When all ofthe pipes are connected and trimmed to length,cable tie neatly in position ensuring no chafes.Note that the blue pulse pipe from the enginebrass pulse union located under the inletmanifold goes to the rearward facing brass pulseunion on the pulse pump.Step 6Check the alignment of the axle sprocket withthe clutch teeth, adjusting as necessary ensuringthat you have sufficient axle key located in thesprocket carrier. Remember that you will needless teeth on the rear sprocket than with a twostroke.Try 12T:68T as a good starting point. Ifthe sprocket carrier does not have sufficientlocation on the key then it can always be turnedaround so its offset can cover the key.Once complete, fit chain and adjust (12mm oftotal up & down movement) ready for use,remembering to fully tighten the clamp bolts.Finally adjust fitment of the fully enclosed plasticchain guard to ensure it does not rub against theexhaust and it is spaced out from axle bearing tosuit the chain alignment.Step 7Fit the exhaust onto the manifold with securingsprings and also locate with springs onto rearcradle. The position of this rear cradle MUST beadjusted to ensure a natural fit with no tensionon the exhaust manifold. IMPORTANT if this isnot done then the exhaust manifold pipe maytouch plastic float bowl on carb during runningwhich will cause dangerous fuel leaks.Please note a special Exhaust Manifold andCranked Exhaust is available for Pro-Karts withbrake discs located in the centre of the axle.Step 8Fit noise box to carb inlet with the twin air inletfilters facing approximately downwards. Noteyou will need a bracket to secure the noise boxfrom its mounting bush to a suitable locationsuch as a securing bolt on the rear axle bearing.Tal-Ko offer a bracket set for its own karts,though every make of kart will require somethingdifferent. It is vital to use such a support bracketand the noise box must always be supportedfirmly in a natural position with no pull on carb asthis will cause the carb rubber inlet connector toengine to fracture.Step 9The carburettor throttle cable will need fitting tothe slide of the carb. Simply remove the carb top(2 Bolts) remove slide assembly and push cablethrough cable swan neck, large spring and outersmall hole in needle retaining plate. Place end ofcable into the slide cable slot and reassemblecarb top. Then thread through outer cable andconnect to the pedal. It is important to ensurethat the pedal locates against a bolt at fullthrottle to prevent damage to the carb or pull onthe rubber inlet connecting manifold.Step 10Next connect the ignition on/off switch. This canbe fitted anywhere suitable, though we providewith the engine a bracket that allows you to fitswitch on the M8 bolt holding the upper plasticsteering column bush to chassis just above thetank. It may well require a new longer length boltwhen this bracket is fitted to allow the bolt to fullyenter the Nyloc part of its securing nut.Connect a red wire from the switch to the sparered short lead coming off the coil unit. Secureneatly. Another lead must be earthed from theswitch to either the chassis or engine. If on theengine we recommend to the earth lead. If thisearth is not good then the switch will not operate.Ensure both wires are neatly secured with cableties or PVC tape. Remember to mark the On/Offpositions.Step 11A radiator catch tank must be used. It can befitted in between bottom of radiator and enginenear clutch guard using a cable tie on bottomradiator bracket.Step 12You will need to drill/cut holes in both the outsideand inside faces of the sidepod to allow accessfor the starter shaft.Refer to the Running Guide to ensure all othersteps are carried out, such as filling with oil andwater before starting the engine.Please note that if you wish to install atemperature gauge then the sensor MUST belocated in the special location hole provided atthe top of the engine. This will have an M10 x 1taper plug in place which should be removedand the sensor fitted with PTFE tape to preventleakage.2