Racing Performance Catalog & Reference GuideVersion (REV. B)

Model/Type: 124335 8105-01 (International) 124335 8104-01 (US Standard)

Table of ConTenTs

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General Specs ............................................................................................................ 3

Special Tools ............................................................................................................... 3

Torque Specs .............................................................................................................. 3

Racing Specifics ......................................................................................................... 3

Optional Performance Parts ...................................................................................... 3

Highlighted Features .................................................................................................. 3

Cylinder Assembly Parts Explode .............................................................................. 4

Head Assembly Parts Explode ................................................................................... 5

Housing & Flywheel Parts Explode ............................................................................ 6

Carburetor Assembly Parts Explode .......................................................................... 7

Clutch Assembly Parts Explode ................................................................................. 8

Starter Assembly Parts Explode ................................................................................ 9

Control Bracket & Gasket Sets Parts Explode ....................................................... 10

PZ26 Carburetor Tuning Guide ......................................................... 11 ..... 15 ..... 19

Electric Starting System Wiring Diagram ........................................ 12 ..... 16 ..... 20

Fuel Pump Diagram ........................................................................... 12 ..... 16 ..... 20

Exhaust System Diagram .................................................................. 12 ..... 16 ..... 20

Air Filter Maintenance ...................................................................... 13 ..... 17 ..... 21

Engine Mounting ............................................................................... 13 ..... 17 ..... 21

Oil ....................................................................................................... 14 ..... 18 ...... 22

Engine Break-In (Running In) ............................................................ 14 ..... 18 ..... 22

Fuel .................................................................................................... 14 ..... 18 ..... 22

Maximum Recommended RPM ........................................................ 14 ..... 18 ..... 22

CONGRATULATIONS on your purchase of a Briggs & Stratton World Formula Racing Engine. This engine has been designed for sanctioned racing only and for use at only sanctioned tracks. It is vital for the longevity and dependability of this product that you read the following, as the initial usage of this engine will affect its life overall.

WE RECOMMEND that all modifications and setup of this engine be done by a reputable source of supply with the proper knowledge needed to work on a racing engine.

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BEFORE OPERATING ENGINE

• ReadentireOperating&MaintenanceInstructionsANDtheinstructionsfortheequipmentthisenginepowers.*

• Failuretofollowinstructionscouldresultinseriousinjuryordeath.

THESE INSTRUCTIONS CONTAIN SAFETY INFORMATION TO• Makeyouawareofhazardsassociatedwithengines• Informyouoftheriskofinjuryassociatedwiththosehazards,and• Tellyouhowtoavoidorreducetheriskofinjury

oPeRaToR safeTYSAFETY AND CONTROL SYMBOLS

Explosion

Toxic FumesMoving Parts

Shock

Hot Surface

Kickback

Fire

Fuel Shutoff

Read Manual

Choke

Oil

Fuel

On Off

Stop

Wear EyeProtection

Slow

Fast

HazardousChemical Frostbite

Thesafetyalertsymbol isusedtoidentifysafetyinformationabouthazardsthatcanresultinpersonalinjury.Asignalword(DANGER,WARNING,orCAUTION)isusedwiththealertsymboltoindicatethelikelihoodandthepotentialseverityofinjury.Inaddition,ahazardsymbolmaybeusedtorepresentthetypeofhazard.

DANGERindicatesahazardwhich,ifnotavoided,will result in death or serious injury.

WARNINGindicatesahazardwhich,ifnotavoided,could result in death or serious injury.

CAUTIONindicatesahazardwhich,ifnotavoided,could result in minor or moderate injury.

NOTICEindicatesasituationthatcould result in damage to the product.

WARNINGCertaincomponentsinthisproductanditsrelatedaccessoriescontainchemicalsknowntotheStateofCaliforniatocausecancer,birthdefects,orotherreproductiveharm.Washhandsafterhandling.

WARNINGTheengineexhaustfromthisproductcontainschemicalsknowntotheStateofCaliforniatocausecancer,birthdefects,orotherreproductiveharm.

WARNINGBriggs&Stratton®Enginesarenotdesignedforandarenottobeusedtopower:fun-karts;go-karts;children’s,recreational,orsportall-terrainvehicles(ATVs);motorbikes;hovercraft;aircraftproducts;orvehiclesusedincompetitiveeventsnotsanctionedbyBriggs&Stratton.Forinformationaboutcompetitiveracingproducts,seewww.briggsracing.com.Forusewithutilityandside-by-sideATVs,pleasecontactBriggs&StrattonEngineApplicationCenter,1-866-927-3349.Improperengineapplicationmayresultinseriousinjuryordeath.

NOTICE:ThisenginewasshippedfromBriggs&Strattonwithoutoil.Beforeyoustarttheengine,makesureyouaddoilaccordingtotheinstructionsinthismanual.Ifyoustarttheenginewithoutoil,itwillbedamagedbeyondrepairandwillnotbecoveredunderwarranty.

WARNINGFuel and its vapors are extremely flammable and explosive.Fire or explosion can cause severe burns or death.

When Adding Fuel• Turnengineoffandletenginecoolatleast2minutesbefore

removingthefuelcap.• Fillfueltankoutdoorsorinwell-ventilatedarea.• Donotoverfillfueltank.Toallowforexpansionofthefuel,donotfill

abovethebottomofthefueltankneck.• Keepfuelawayfromsparks,openflames,pilotlights,heat,andother

ignitionsources.• Checkfuellines,tank,cap,andfittingsfrequentlyforcracksorleaks.

Replaceifnecessary.• Iffuelspills,waituntilitevaporatesbeforestartingengine.

When Starting Engine• Ensurethatsparkplug,muffler,fuelcapandaircleaner(ifequipped)

areinplaceandsecured.• Donotcrankenginewithsparkplugremoved.• Ifenginefloods,setchoke(ifequipped)toOPEN/RUNposition,move

throttle(ifequipped)toFASTpositionandcrankuntilenginestarts.

When Operating Equipment• Donottipengineorequipmentatanglewhichcausesfueltospill.• Donotchokethecarburetortostopengine.• Neverstartorruntheenginewiththeaircleanerassembly(if

equipped)ortheairfilter(ifequipped)removed.

When Changing Oil• Whenyoudraintheoilfromthetopoilfilltube,thefueltankmust

beemptyorfuelcanleakoutandresultinafireorexplosion.

When Transporting Equipment• TransportwithfueltankEMPTYorwithfuelshut-offvalveOFF.

When Storing Fuel Or Equipment With Fuel In Tank• Storeawayfromfurnaces,stoves,waterheatersorotherappliances

thathavepilotlightsorotherignitionsourcesbecausetheycanignitefuelvapors.

* Briggs & Stratton does not necessarily know what equipment this engine will power. For that reason, you should carefully read and understand the operating instructions for the equipment on which your engine is placed.

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Briggs & stratton does not approve or authorize the use of these engines on 3 wheel all terrain vehicles (atvs), motor Bikes, fun/recreational go-karts, or aircraft products. use of these engines in such applications could result in property damage, serious injury (including paralysis), or even death. this engine requires special technical expertise and preparation Before it can Be used in competitive events.

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WARNINGStarting engine creates sparking.Sparking can ignite nearby flammable gases.Explosion and fire could result.

• IfthereisnaturalorLPgasleakageinarea,donotstartengine.• Donotusepressurizedstartingfluidsbecausevaporsareflammable.

WARNINGEngines give off carbon monoxide, an odorless, colorless, poison gas.Breathing carbon monoxide can cause nausea, fainting or death.

• Startandrunengineoutdoors.• Donotstartorrunengineinenclosedarea,evenifdoorsorwindows

areopen.

WARNINGRapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than you can let go.Broken bones, fractures, bruises or sprains could result.

• Whenstartingengine,pullthestartercordslowlyuntilresistanceisfeltandthenpullrapidlytoavoidkickback.

• Removeallexternalequipment/engineloadsbeforestartingengine.• Direct-coupledequipmentcomponentssuchas,butnotlimitedto,

blades,impellers,pulleys,sprockets,etc.,mustbesecurelyattached.

WARNINGRotating parts can contact or entangle hands, feet, hair, clothing, or accessories.Traumatic amputation or severe laceration can result.

• Operateequipmentwithguardsinplace.• Keephandsandfeetawayfromrotatingparts.• Tieuplonghairandremovejewelry.• Donotwearloose-fittingclothing,danglingdrawstringsoritemsthat

couldbecomecaught.

WARNINGRunning engines produce heat. Engine parts, especially muffler, become extremely hot.Severe thermal burns can occur on contact.Combustible debris, such as leaves, grass, brush, etc. can catch fire.

• Allowmuffler,enginecylinderandfinstocoolbeforetouching.• Removeaccumulateddebrisfrommufflerareaandcylinderarea.• ItisaviolationofCaliforniaPublicResourceCode,Section4442,

touseoroperatetheengineonanyforest-covered,brush-covered,orgrass-coveredlandunlesstheexhaustsystemisequippedwithasparkarrester,asdefinedinSection4442,maintainedineffectiveworkingorder.Otherstatesorfederaljurisdictionsmayhavesimilarlaws.Contacttheoriginalequipmentmanufacturer,retailer,ordealertoobtainasparkarresterdesignedfortheexhaustsysteminstalledonthisengine.

WARNINGUnintentional sparking can result in fire or electric shock.Unintentional start-up can result in entanglement, traumatic amputation, or laceration.Fire hazard

Before performing adjustments or repairs:• Disconnectthesparkplugwireandkeepitawayfromthesparkplug.• Disconnectbatteryatnegativeterminal(onlyengineswithelectric

start).• Useonlycorrecttools.• Donottamperwithgovernorspring,linksorotherpartstoincrease

enginespeed.• Replacementpartsmustbeofthesamedesignandinstalledinthe

samepositionastheoriginalparts.Otherpartsmaynotperformaswell,maydamagetheunit,andmayresultininjury.

• Donotstriketheflywheelwithahammerorhardobjectbecausetheflywheelmaylatershatterduringoperation.

When testing for spark:• Useapprovedsparkplugtester.• Donotcheckforsparkwithsparkplugremoved.

WoRlD foRMUlaGeneRal sPeCsModel: 124335 Type: 8104/8105 Displacement: 12.48 Cu. in. - 205 cc Design: Slant, 30 degree,Overhead Valve, Electric Start Bore: 2.6875/2.6885 in. (68.3mm)Stroke: 2.2 in. (55.9mm)Compression Ratio: 9.5 to 1 Factory Timing: 29 degrees BTDC

HIGHlIGHTeD feaTURes· Dual Ball-Bearing, RACING Reinforced Cylinder· Billet Rod· Slotted, Stelite-Faced, Ground Cam w/ Compression Release· Dual, High-Silicon Valve Springs· PVL™ Digital Ignition System w/ 7,100 RPM Limiter· CNC D-Shape Intake Port· Walbro™ Round-Slide Carburetor· Dana™ Fire-Ring Head Gasket· Racing Crankshaft w/ Induction-Hardened Crankpin· Green™ Air Filter· Federal Mogul™ Moly-Coated Cam Ground, Barrel-Faced Piston· Chrome-Faced, Racing Only Ring Package· Port-Liner, Exhaust System· Mikuni™ Fuel Pump· Noram™ Clutch w/ Quick Change Sprocket Set· Automotive 3-Piece Valve Retainer System· Beefy Rocker Arm Stud Nuts

sPeCIal Tool ReQUIReMenTsGeneral Model 12 Manual Part No. 276781 PVL™ Flywheel Puller Part No. 19584Flywheel Wrench Part No. 19433

ToRQUe sPeCsDescription Wrench/socket size torqueair guard 7mm 40-50 lb-in. (4.5-5.6 nm)Blower housing 10mm & 3/8" 60-110 lb-in. (7-12.5 nm)carburetor (to manifold) 10mm 80-110 lb-in. (9-12.4 nm)connecting rod t27 140-150 lb-in. (16-17 nm)cylinder head Bolts 10mm 200-220 lb-in. (20-27 nm)exhaust Brace screws 10mm 95-125 lb-in. (11-14 nm)exhaust stud 10mm 95-125 lb-in. (11-14 nm)flywheel nut 15/16 55-75 ft-lbs. (74.5-101 nm)flywheel fan 10mm 180-240 lb-in. (20-27 nm)intake (to cylinder) 5mm allen 70-90 lb-in. (8-10.2 nm)oil drain plug 3/8" 100-125 lb-in. (11-14 nm)pvl™ module 7mm 20-35 lb-in. (2.3-4 nm)rocker arm stud us-7/16”, metric-10mm 90-120 lb-in. (10-14 nm)rocker arm plate 10mm 70-90 lb-in. (7.9-10.1 nm)rocker arm set screw us-1/8" allen, metric-4mm 50-70 lb-in (5.6-7.9 nm)spark plug 5/8" deep 95-145 lb-in. (11-16.4 nm)side cover 10mm 95-125 lb-in. (11-14 nm)starter gear #2 phillips 35-53 lb-in. (4-6 nm)top control plate 10mm 70-90 lb-in. (8-10 nm)valve cover 10mm lower & 3/8" 30-60 lb-in. (3.5-7 nm)

RaCInG sPeCIfICsPVL™ Ignition Module Gap - .010/.014 (.15/.36mm)Digital Rev Limiter - 7,100 RPM +/- 50Spark Plug - Champion™ RG4HCFuel Requirements - 98 Octane (RON)Recommended Oil Capacity – 14-16 oz. of Briggs & StrattonSynthetic 4T Racing Oil custom blended by Amsoil. This oil isavailable through your current Briggs & Stratton or Amsoilsource of supply. The use of ‘karting’ oils or automotive oils(use only during initial break-in) are no longer recommendeddue to their severe limitations that could impact the life ofyour engine.Exhaust System Requirements-50mm x 57mm Flex Coupling,50/90 Canister Muffler.Starter System-12 Volts @ 20 Amp Capacity-180 Cold Cranking amps. Refer to your sanctioning body rules for required installation location.

oPTIonal PeRfoRManCe PaRTsHigh - G/Force Breather Bypass System - Part No. 555688Magnetic Drain Plug - Part No. 691663Gearbox Splined Crankshaft - Part No. 5557226-1 Gearbox Complete - Part No. 555721 Electric Starter Kit - Part No. 555703Fuel Filter - Part No. 394358B

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NO COMPROMISES.

At the end of the day the effort you put into racing directly determines your outcome. You wouldn’t compromise on your approach to racing, so why would you with your oil? What if there was an oil engineered specifically for high-revving, air-cooled racing engines, methanol or gas fuels, that gives you the power of a lite oil yet the wear protection of a heavy oil? What if that oil also had the added benefits of wear protection and a corrosion inhibitor to safeguard your investment during, between, and after the season was over?

Briggs & Stratton 4T Racing Oil is available through any authorized Briggs & Stratton Racing dealer. For additional information or to locate a dealer near you please visit www.briggsracing.com.

Part Number: GBS2960

COMPROMISES lEAd TO WhAT-IF’S ANd AS RACERS ThAT ISN’T PART OF OuR dNA. NO MORE COMPROMISES.

INTROduCING ThE BRIGGS & STRATTON 4T Full SYNThETIC OIl CuSTOM ENGINEEREd BY AMSOIl®. MAXIMuM hORSEPOWER

OuTSTANdING WEAR PROTECTION

EXCluSIVE SYNThETIC FORMulATION

EXhAuSTIVElY TESTEd ON ThE dYNO ANd ON ThE TRACK

dESIGNEd FOR hIGh REVVING, AIR-COOlEd RACING ENGINES

WoRlD foRMUla cylinder assembly(engine Model series 124335)

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799318 Screw(crankcase cover/sump - M7x1)

555652 Crankshaft Endplay Shim(contains (4) .005, (1) .015)

555706 Crankcase Cover

281658s Oil Fill Cap•

557041 Camshaft

690979 Timing Key† (0.370”)798972 Timing Key† (0.491”)

691866 Piston Pin Lock

499423 Piston Pin

557117 Connecting Rod

222698S Flywheel Key

690824 Ball Bearing†690959 Locating Pin*

555705 Cylinder Assembly

691686 Oil Drain Plug*691663 Oil Drain Plug(Magnetic, optional)

557117 Connecting Rod

692550 Oil Seal•(pto side)

281658S Oil Fill Cap•

798538 Ball Bearing•

695087 Timing Gear†

557137 Crankshaft

699485 Crankcase Gasket•

699483 Metric Screw(cylinder shield)

555680 Cylinder Shield

692600 Breather Tube555140 Bushing/Seal Kit

299819s Oil Seal(Magneto side)

792723 Flywheel Nut†

Included with Respective Piston Assembly (includes all parts shown)

† Included with 557137 Crankshaft

Included with 499423 Piston Pin

691664 Screw(connecting rod)

555688 Breather Assembly(optional, Also includes 691890 rocker cover Gasket)

*Included with 555705 Cylinder Assembly (includes all parts shown)

557121 Piston Assembly(std., with File to fit top ring)557122 Piston Assembly(.10" over, with File to fit top ring)557123 Piston Assembly(.20" over, with File to fit top ring)557124 Piston Assembly(.30" over, with File to fit top ring)

555664 Ring Set (std.)555665 Ring Set (.10” over)555666 Ring Set (.20” over)555667 Ring Set (.30” over)

555692 Ring Set(.010” over compression ring)

555693 Ring Set(.020” over compression rings)

555694 Ring Set(.030” over compression ring)

55513 Ring Set(.10” over - contains 10 top rings)55514 Ring Set(.20” over - contains 10 top rings)55515 Ring Set(.30” over - contains 10 top rings)

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•Included with 555706 Crankcase Cover

WoRlD foRMUla head assembly(engine Model series 124335)

691890 Rocker Cover Gasket

699230 Hex Washer Head Metric Screw(rocker cover Bottom)

555679 Rocker Cover

694543 Rocker Arm Adjuster*1(us – 694543, Metric – only available in 797440 kit)

694544 Rocker Arm Stud*1(us- 694544, Metric - 797441)

557015 Rocker Arm*

557025 ValveRetainer*

557024 ValveSpring*(intake & exhaust)

699230 Hex Washer Head Metric Screw(cylinder head plate)

691343 Push Rod Guide*

698214 Cylinder Head Plate*1(us – 698214, Metric – 797442 - both include 694088)

694088 Cylinder HeadPlate Gasket*

693517 Push Rod

557098 Valve Tappet

557018 Exhaust Valve*

557017 Intake Valve*

555698 Cylinder Head Gasket

557133 Cylinder Head Assembly

555645 Replacement Valve Guide Bushing*(.002 over)

557039 Spark Plug

557045 Exhaust Manifold

*Included with 557133 Cylinder Head Assembly

557016 Valve Cap*

557099 Washer*(intake Manifold)

699482 Hex Washer Head Metric Screw*(cylinder head - M8 x 1.25)

692557 Hex Washer Head Screw(rocker cover top & sides - 1/4”-20 unc)

555690 Heat Disperser

691764 Hose Connector

555646 Nut*(intake Manifold)

557108 Stud(intake Manifold)

557026 RetainingRing* (exhaust)

557099 Washer(exhaust Manifold)

557097 Stud (exhaust Manifold)

691893 Exhaust Gasket

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1 - Note Metric and US standard rocker arm systems are not interchangeable.

WoRlD foRMUla housing & flywheel(engine Model series 124335)

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557125 Magneto Armature

557126 Flywheel Assembly

695287 Rewind Starter

692591 Flywheel Cup (optional)

19069 Flywheel Puller

19433 Flywheel Wrench

794954 Metric Screw(rewind)

699477 Metric Screw(Magneto Armature)

557134 Blower Housing

698039 StarterDrive Cover

699200 Screw (starter Drive cover)

792723 Hex Jam Nut(Flywheel - M16 x 1.5)

794451 Hex Washer Head Metric(Blower housing - 5/16 - 18unc)

794451 Hex WasherHead Metric Screw(Blower housing - M6 x 1)

557128 Starter Ring Gear(includes 4 pcs. 557129 - screw)

19584 Flywheel Puller

699201 Screw(Flywheel Fan)

695630 Stop Wire(used on type no. 8105 & 8105)

555255 Rewind Guard

555702 Blower Housing Shield(optional)

699200 Hex Washer Head Screw

692592 Flywheel Fan

WoRlD foRMUla carburetor assembly(engine Model series 124335)

557081 Needle Jet

557083 Throttle Valve

555255 Pilot Jet

557012 Main Jet (Gasoline - contains: 36 & 40 mm pilot jets: 90, 93, 98, 102, and 100 main jets)

555648 Float Needle Valve

557080 Carburetor Float

557082 Float Bowl Gasket*

557008 Float Bowl (includes Bowl Drain)

555610 O-Ring Seal

557044 Intake Gasket*

557130 Carburetor Spacer+

557007 O-Ring Seal*

557086 Emulsion Tube

555586 Idle Speed Kit

557084 Idle Speed Kit(Longer spring/needle)557085 Idle Mixture kit (stock length)

557087 ThrottleReturn Spring

557088 ThrottleCable Cap

555650 Needle ValveRetainer (contains 5 clips & 5 retainers)

555647 ThrottleCable Boot

*557089 Carburetor Overhaul Kit

557006 Carburetor Assembly(Does not contain carb spacer, clamp, Manifold, Gasket, Air cleaner or Main Jet)

557131 Clamp(intake Manifold)

557009 Intake Manifold

698973 Air Cleaner

*

557096 Air Cleaner(Water repellent cover,

optional)

+555646 Metric Screw/Nut Kit (carb to spacer)

690939 Nut+(carburetor)

Air Cleaner Recharging Kit(Available through GreenFilterUSA.com)

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WoRlD foRMUla clutch(engine Model series 124335)

557115 Snap Ring

557116 Cartridge Springs Kit(includes 3 orange & 3 Yellow)

557114 Clutch Cartridge(includes orange springs)

557112 Clutch Hub Shaft

557113 Clutch Thrust Spacer/Bearing

557019 Mounting Hardware

557111 Clutch Drum

557115 Snap Ring

Noram Part Number2400025 Radius Washer(required for inboard mounting,included with clutch Assembly)

557020 Clutch Gear (17t, #219)557021 Clutch Gear (16t, #219)557092 Clutch Gear (19t, #219)557091 Clutch Gear (18t, #219)

557023 Centrifugal Clutch Assembly(Does not contain radius Washer 2400025)

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WoRlD foRMUla starter assembly(engine Model series 124335)

691286 End Cap*

557120 Screw(support Bracket)

557119 Starter Motor Bracket

691293 Brush Retainer*

497608 Brush Set*+

Starter Housing*

Starter Armature*691261 Washer*+(Brush retainer)

694482 Drive Cap*

691029 Nut*+(Brush retainer)

690323 Screw*(starter Motor)

793567 Screw(starter Motor Mounting M8 x 1.25-20.3 mm)

691265 Retaining Ring

692353 Pinion Gear

499308 Starter Drive*

557067 Starter Solenoid

691532 Starter Strap

690635 Clamp(starter solenoid)

+Included with 691293 Brush Retainer

*Included with 557068 Starter Assembly

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WoRlD foRMUla control bracket & gasket set(engine Model series 124335)

699479 Metric Screw(control panel)

555699 Control Panel

557028 Starting Switch

699485 Crankcase Gasket*557044 Intake Gasket*+ 694088 Cylinder Head Plate Gasket*+

691890 Rocker Cover Gasket*+

555698 Cylinder Head Gasket*+692550 Oil Seal*(pto side)

299819s Oil Seal*(Magneto side)

+ Included with 557027 Valve Gasket Set

*Included with 557110 Engine Gasket Set

793379 Stop Wire(used on type no.(s) 8104 - 8105)

808656 Fuel Pump

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PZ26 CaRbUReToR TUnInG GUIDe

Walbro PZ CarburetorTheWalbroPZ26hasbeenspecificallycalibratedforthisapplication.Thefollowingguideshouldhelpyouwithset-upandmaintenance.Replacementcomponentsareavailablethroughyourauthorizedsourceofsupply.Anadditionaljetkitisalsoavailableat557012.Thiskitwasspecificallyde-signedtocoverthemajorityofyourgasolinejettingrequire-ments.

float HeightThefloatheightcontrolsthefuellevelinthefloatbowl,whichcanalsoeffectcarburetorperformance.Setfloatheightaccordingtospecificationbeforeanyothertuning.Thefloatheightmayneedtobeadjustedforbestperfor-manceondifferenttracktypes.

Idle / low speedTuningoftheengineatidleandlowspeedsisaccomplishedbyadjustingtheIdleMixtureScreworchangingthesizeofthePilotJet(alsocalledSlowJet).Thejetsizeordiameterinmillimetersisstampedonthejet(37=.37mmorifice).TheIdleMixtureScrewisafueladjustment,soclosingthescreworturningitclockwisewillleanthefuelmixture,andopeningthescreworturningitcounterclockwisewillrichenthefuelmixture.

ToadjusttheIdleMixtureScrewproceedasfollows.TurntheIdleMixturescrewinuntilitlightlyseatsorstops.Backthescrewoutthespecifiednumberofturns.WarmtheengineandsettheIdleSpeedscrewslightlyhigherthanthedesiredidlerpm.TurntheIdleMixturescrewinorouttoobtainthehighestrpm.TurntheIdleSpeedscrewtothedesiredidlerpm.Aslightlyrichidlemixtureisusuallybet-terforacceleration.

IfasmoothidlecannotbeobtainedwiththeIdleMixturescrewbetween1/4-2turnsoutfromclosed,adifferentsizePilotJetmaybeneeded.ThepropersizePilotJetwillallowforsmoothaccelerationfromanidleandsteadyenginespeedupto1/4throttleopening.

Midrange / Part ThrottleTheJetNeedleprimarilycontrolsfuelflowbetween1/4and3/4throttleopening.TheJetNeedlehasfivenotchesandaC-cliponthetopofit.Torichenthepartthrottleoperation,movethecliptothenextlowernotch.Thiswillholdtheneedlefartheroutofthenozzle.Toleanthepartthrottleoperation,movethecliptothenexthigherposition.Thehighestnotch(farthestfromthenarrowtip)isconsideredthe1stposition.Needletaperreferencelettersarestampedontheneedleforidentification.

High speed / full ThrottleTheMainJetcontrolsthefuelflowatthrottlepositionsof1/2tofullthrottle.Thejetsizeordiameterinmillimetersisstampedonthejet.AltitudeandweatherconditionscaneffecttheengineoperationenoughtorequirechangingthesizeoftheMainJet.Highairtemperature,humidity,oraltitudecouldrequireasmallerMainJet.Lowtemperature,humidity,oraltitudewouldrequirealargerdiameterMainJet.RunningtheenginewithanimproperMainJetcouldresultinalossofpower,highenginetemperatures,orenginedamage.

startingThiscarburetorisequippedwithachokevalveforstarting.Whentheengineiscold,liftchokelevertostartengine.Asenginewarmspushchokeleverdowntoopenchokefornormaloperation.

CAUTION: After connecting the throttle cable to the throttle slide valve or after EVERY TIME the throttle slide is removed, always remove air filter and visually check that the throttle slide closes fully and moves freely in the bore.

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Bowl Screws 17 – 20 in-lbs

Pilot Jet 9 – 12 in-lbs

Needle Jet 14 – 16 in-lbs

Main Jet 9 – 11 in-lbs

Torque SpecificaTionSGaSoLine pZ carbureTor GeneraL SpecificaTionS

Main Jet #96

Pilot Jet (Slow Jet) #37

Jet Needle CDB 4th notch

Main Nozzle Diameter 2.6 mm

Idle Mixture Screw turns out 1-1/2

Float Height* 14.0 mm

eleCTRICal sCHeMaTICThissystemisdesignedfora12-voltpowersupply.Formostracingapplications,ahigh-quality,gelcellbattery(determinedbyyourauthorizedsanctioningbody)withatleastan8-amphourratingisrecom-mended.An8mmpositivebatterycableisrequiredbetweenthebatteryandstartersolenoid.Holdingdownthestartingswitch,Part#557028,willturntheignitionOFF,andislocatedonthecontrolpanel,Part#555699.

Seestarterwiringschematicforstarterswitchandbatterycableconnections.

Warning–ToavoidpossibilityofdamagetoyourenginesdigitalignitionmoduleCOMPLETELYDISCONNECTboththepositiveandnegativeleadstoisolatethebatteryforcharging.Followallchargingmanufacturerrecommendations.

FUEL PUMP 808656

PULSE LINE

FUEL FILTER

REMOTEFUELSOURCE PULSE FITTING

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Electric Start Wiring Diagram

fUel PUMPThefollowingdiagramshowstherecommendedlayoutforattach-ingthefuelpumptoyourWorldFormularacingengine.AMikunifuelpumpissupplied.Thefuelpumpshouldbeinstalledasrecom-mendedbyyourlocalCIKorganiza-tion.Werecommendthatthisfuelpumpbeplacedinalocationthatisn’taffectedbyheat.Thepulselineismarkedwitha“P”onthefuelpump.Thisshouldbeconnectedwithanon-collapsiblefuelline(specificallymadeforfuelapplica-tions)tothefittingonthetopoftheintakemanifold.Theothertwofit-tingsonthefuelpumphavearrowstoshowtheinletandoutletofthepump.Pleaserefertotheaccompa-nyingdiagram.

cauTion: WE HIGHLY RECOMMEND THAT YOU USE A 75 MICRON FUEL FILTER. THIS SHOULD BE PLACED IN-LINE BETWEEN THE TANK AND THE FUEL PUMP.

eXHaUsT sYsTeMTheheaderpipehasbeentunedanddesignedtoberunwiththefollowingparts:A)50mmdiameterx57mmlength

flexcoupling(notincluded)B)CIKapproved50/90“2-stroke”

muffler(notprovided)C)Three(3)exhaustsprings(not

provided)

EXHAUST SPRINGS

REAR KART BRACKET SUPPORT

FLEX COUPLING

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GReen aIR fIlTeR• ThereisadifferenceintechnologywithastandardpaperairfilterandyournewGreenHighPerformanceAirFilter.

• Paperfiltersstopdirtbybeingmadeupofsmallholeswhichallowtheairtopassbutnotthedirt.Unfortunatelythisisveryrestrictivetoyourengine.Aftereachparticleofdirtisstoppedthefilterbecomesthatmuchmorerestrictive,untilairflowishaltedtoalmostnothing,starvingyourengineofair.Thisdrasticallydecreasesyourengine’sperfor-mance.

• ForbestperformanceitisrecommendedyourGreenFilterbecleanedandoiledbetweeneachrace.

• GreenFilterismadeofwovencottonthatMUSTbeoiled.AGreenFilterstopsdirtdifferentlythanapaperairfilter.GreenHighPerformanceAirFiltersaredesignedtobeoiled.Theoilcreatesapositive(+)magneticchargewiththestainlesssteelmesh,whichattractsthenegatively(-)chargeddustparticles.Thedustanddirtbuildsaroundthemeshtoformatunnel.Thisallowsthecottontoremaincleanerformaximumairflow,butstillstopsthedirt.ThatiswhyitisimportanttokeepyourGreenAirFilterproperlyoiled.

• YourGreenFiltercomespre-oiledfromthefactory,butaftereach5-10hoursofracingthefiltershouldbecheckedforcloggingandre-oiled.(Thisisbasedonnormalraceconditions.Ifracingisonadirttrackorindirtyconditionsthefiltermustbecleanedmorefrequently.Extremecasescleanevery1-2hrs.ofracetime).

Cleaning instructions:1. Removeasmuchdirtfromthefilteraspossiblebytappingitonahardsurface.

2. UsingtheGreenFilterCleaning&Re-OilKit(Part#2000),spraythefilterwithGreenFiltercleaner.Allowthesolutiontosoakintothefilterforabout15minutes.Ordilutethecleanerinabucketofwaterandsoakthefilter.

3. CAUTION:Neverusestrongdetergents,highpressurewater,orgasoline.

4. Rinsethefilterwithwarmwater,insidefirstandthenoutside.(Letthewaterrunfromthecleansidetothedirtyside.)

5. Allowthefiltertodrycompletely.Itisbesttoallowthefiltertodrynaturally.Don’tuseheat,thismightshrinktheCotton.

6. Re-oilthefilterusingGreenFilteroilONLY(kit#2000).Don’tuseothercottonfilteroils,thecolorisdifferent(GreenoiliscoloredgreenandisspeciallyformulatedforGreenFilters).

*YouwillknowwhenthefilteriscorrectlyoiledbythecottonchangingfromwhitetoGreen.(Itwilllookwet.)

* CAUTION: Be sure not to over oil your filter, which can damage your sensors and engine.

Allowfiltertodryfor½hour.IfyouplaceyourGreenFilteronapieceofcardboardfor10minutesanditleavesoilstains,youhaveoveroiledyourfilter.Cleanandstartover.

WARNING: Never use motor oil, transmission fluid, WD 40. Failure to follow instructions can cause fires resulting in death, bodily injury or property damage.

The Green Filter cleaning and re-oil kit is Part #2000. For more information and/or questions, please visit www.greenfilterusa.com.

enGIne MoUnTInGThisengineisdesignedtobemountedFLATonthekart.Becauseofthecarburetorsetupandoilingsystem,weDONOTrecommendmountingtheenginewithanydegreeofangle.

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oIl Oilisthelifelineofanyengineandusingahighqualityoilisamust.

Werecommendusing14-16oz.ofBriggs&StrattonSynthetic4tRacingOilcustomblendedbyAmsoil.Thisoilisavail-ablethroughyourcurrentBriggs&StrattonorAMSOILSourceofsupply.Theuseof‘karting’and/orstandardautomo-tiveoils(beyondbreak-in)isNOTrecommendedduetotheirseverelimitationsandpotentialtoadverselyimpactthelifeofyourengines.

Note:Foryourenginebreak-inperioduseONLYahigh-gradeSAErated,non-synthetic30weightoil.Theuseofsyntheticoilduringthisprocesscouldpreventproper‘seating’ofthepistonrings,etc..

enGIne bReak-In (RUnnInG In)Thefirst30minutesofthisengine’slifearethemostimportanttoensuretrouble-freeracing.Aftermountingtothekart,werecommendthattheenginebebrokeninusinganyhighgradenon-syntheticSAE-rated30weightoil.Runtheengine,noload,atidle(1,700-2,000rpm)toallowtheenginetoreachnormaloperatingtemperature(5-8minutes).Shuttheengineoffandallowtoreturntoroomtemperature.

Againstartuptheengineandbringuptotemperature(5-8minutes).Shutoffengineandchangetheoil.Replacetheoil(16-18ounces)anditistimetoplace‘load’ontheengine.Toapplyaloadontheenginetheeasiestwaytodothisistoruntheengineonthetrack.Runningnothigherthan6,000rpm,takeseverallaps(dependingoncourselength).Withtheoilstillwarmdrainandreplacetheoil.Repeatandslowlybegintobringtheengineuptospeed.

fUel Thisenginewasdesignedfor98Octane(RON)or93Octane(RON+MON/2)pumpgas.Theuseofloweroctanefuelscouldcauseenginedetonationand/oradverselyaffectyourengine’slife.

MaXIMUM ReCoMMenDeD RPM YourenginehasbeenequippedwithagovernorsystemthatwilllimittheRPMofthisenginetoaround7,100RPM+50RPM.Thisdoesnottakeawayfromtheneedtohaveareturntoidlemechanism.Removalortamperingofthissystemcouldleadtoreducedenginelife,and/orseriousinjury,possiblyevendeath.Also,wedonotrecommendrepetitiveuseoftherevlimiterasalimitingfactorofRPM.Thisrevlimiterworksbyactively‘shorting’theignitionsystemofyourengine.Inrepetitivesituationsfuelloadingaswellasincreasedinternalstressloadoftheenginecanoccur,greatlyreducingenginelife.

IGnITIon MoDUle/Rev lIMITeR – PaRT #557125

Donotdisconnectormodifytheinstalledrevlimiter.Engineoverspeedingcanresultinflywheelfailureorpartfailure,causingdeath,seriousinjuryorpropertydamage.

WarninG

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CaRbURaDoR WalbRo PZ

CaRbURaDoR WalbRo PZElWalbroPZ26hasidoespecíficamentecalibradoparaestaaplicación.Lasiguienteguíaloayudaráenelajusteyelmanten-imiento.Loscomponentesderepuestoestándisponiblesatravésdesudistribuidorautorizado.Sedisponedeunkitadicionaldebo-querelenelkit #557012–Estekitfueespecificamentediseñadoparacubrirlamayoríadelosrequerimientosdelosboquerelesdegasolina.

altura del flotadorLaalturadelflotadorcontrolaelniveldecombustibleenlatazadelflotador,locualpuedeafectartambiéndeldesempeñodelcarbu-rador.Ajustelaalturadelflotadordeacuerdoalaespecificaciónantesdehacercualquierotroajuste.

Ralentí / baja velocidadTLaafinacióndelmotorparavelocidadderalentiyvelocidadesmínimasvieneacompañadaporelajustedelTornillodeMezcladeRalentíoporelcambiodeltamañodelBoquerelPiloto(cono-cidotambiéncomoelBoquereldeBajaVelocidad).Eltamañodelboquereloeldiámetroenmilímetrosvienegrabadoenelboquerel(38=orificiode.38mm).ElTornillodeMezcladeRalentíesunajustedecombustible,demaneraquesisecierraeltornilloosegiraensentidodelasagujasdelrelojseempobrecerálamezcladecombustible,ysiseabreeltornilloosegiraensentidocontrarioaldelasagujasdelrelojseenriquerecerálamezcladecombustible.ParaajustarelTornillodeMezcladeRalentíprocedacomoseindicaacontinuación.GireelTornillodeMezcladeRalentíhacia

adentrohastaqueesteligeramenteseasienteosedetenga.DevuelvaelTornillohaciafueraelnúmerodegirosespecificados.CalienteelmotoryajusteelTornillodeMezcladeRalentíhaciaadentroohaciafueraparaobtenerlasrpmmásaltas.GireelTornillodeMezcladeRalentíalasrpmderalentideseadas.Unamezcladeralentiligeramentericaesusualmentemejorparalaaceleración.SinosepuedeobtenerunavelocidadderalentiuniformeconelTornillodeMezcladeRalentíentre1/4–2giroshaciaafueradesdelaposicióncerrado,puederequerirseunBoquerelPilotodediferentetamaño.ElBoquerelPilotodeltamañoadecuadolepermitiráunaaceleraciónsuavedesdeunavelocidadconstanteyderalenticonunaaberturade1/4delacelerador.

Rango Medio / aceleración ParcialLaagujadelboquerelcontrolaprincipalmenteelflujodecom-bustibleentre1/4y3/4deaberturadelacelerador.LaagujadelboquereltienecincomuescasyunapinzaenCenlapartesuperiordeesta.Paraenriquecerlaoperaciónparcialdelacel-erador,muevaelclipalasiguientemuescaqueseencuentramásabajo.Estosostendrálaagujaqueseencuentramáslejosadistanciadelatobera.Paraempobrecerlaoperaciónparcialdelacelerador,muevaelcliphacialasiguienteposiciónmásalta.Lamuescamásalta(laqueseencuentramáslejosdelapunta)esconsideradacomola1a.posición.Lasletrasdereferenciadelahusamientodelaagujavienengrabadasenlaagujaparasuidentificación.

alta velocidad / aceleración TotalElboquerelprincipalcontrolaelflujodecombustibleenlasposi-cionesde1/2aceleradoryaceleracióntotal.Eltamañodelbo-quereloeldiámetroenmilímetrosvienegrabadoenelboquerel.Laaltitudylascondicionesclimáticaspuedenafectarlaoper-acióndelmotorlosuficientepararequerirelcambiodeltamañodelBoquerelPrincipal.Laaltatemperaturadelaire,lahumedad,olaaltitudpodríanrequerirunBoquerelPrincipalmáspequeño.Labajatemperatura,lahumedad,olaaltitudpodríanrequerirunBoquerelPrincipalconundiámetromásgrande.

aRRanQUeEstecarburadorestáequipadoconunaválvuladeestranguladorparaelarranque.Cuandoelmotorestéfrío,levantelaválvuladelestranguladorparadararranquealmotor.Amedidaquesecalienteelmotorpresionelapalancadelestranguladorparaabrirelestranguladorparaunaoperaciónnormal.

PRECAUCION: Después de conectar el cable del acelera-dor con la válvula multifuncional del acelerador o después de CADA VEZ que se remueva la válvula multifuncional del acelerador, remueva siempre el filtro de aire y compruebe vi-sualmente que la válvula multifuncional del acelerador cierre completamente y se mueva con libertad en el trayecto.

Tornillos Taza 17 – 20 in-lbs

Boquerel Piloto 9 – 12 in-lbs

Boquerel Aguja 14 – 16 in-lbs

Boquerel Principal 9 – 11 in-lbs

eSpecificacioneS de TorqueeSpecificacioneS GeneraLeS deL carburador pZ 26

Boquerel Principal #96

Boquerel Piloto (Slow Jet) #37

Aguja del Boquerel CDB 4th notch

Diámetro del Boquerel Principal 2.6 mm

Giro hacia fuera del Tornillo 1-1/2 de Mezcla de Ralentí 1-1/2

Altura del Flotador* 14.0 mm

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Resorte

VálvulaMultifuncionaldelAcelerador

KitdelBoquerelAguja

KitdelaCubiertadelCabledelAcelerador

ConjuntoEstrangulador

TornillodeVelocidaddeRalentí

KitFlotador

ToberaPrincipal

MezcladeRalentí

EmpaqueTazaFlotador

AgujadeEntrada&Pinza

TubodeEmulsión

BoquerelPiloto

BoquerelPrincipal

KitBoquereldeGasolina(DisponiblePróximamente)

KitTazadelFlotador

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esQUeMa eleCTRICoEstesistemaestádiseñadoparaunsuministrodeenergíade12-voltios.Paralamayoríadeaplicacionesdeeventoscompetitivosserecomiendaunabateríadealtacalidad,conceldasdegel(determinadaporsucuerpodeaprobaciónautorizado)conunacla-sificacióndeporlomenos8amperioshora.Serequeireuncablepositivodebateríade8mmentrelabateríayelsolenoidedearranque.Elsuichedeapagado,Parte#557028,apagaráelencendido,yseencuentralocalizadoenlatapaplásticadelmotor,Parte#555699.

Consulteelesquemadelcableadodelarranqueparalasconexionesdelsuichedearranqueyelcabledelabatería.

boMba De CoMbUsTIbleElsiguientediagramamuestraladisposiciónrecomendadaparasujetarlabombadecombustibleasumotordecarrerasWorldFormula.

Sesuministraunabombadecom-bustibleMikuni.Labombadecom-bustibledebeserinstaladasegúnlorecomendadoporsuorganizaciónlocalCIK.Recomendamosqueestabombadecombustibleseacolocadaenunalocalizaciónquenoseveaafectadaporelcalor.Lamangueradepulsaciónestámarcadaconunaletra“P”enlabombadecombustible.Estadebeserconectadaconunamangueradecombustibleno-plegable(fabricadaespecialmenteparaaplicacionesdecombustible)alacceso-rioenlapartesuperiordelmúltipledeadmisión.Losotrosdosaditamentosenlabombadecombustibletienenflechasquemuestranlaentradaylasalidadelabomba.Porfavorrefiérasealdiagramaqueloacompaña.

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Esquema del Sistema de Cableado del Arranque Eléctrico

SUICHEDEARRANQUE

PARAELMONTAJEDELMOTOR

BATERÍADE12V

ARRANQUEYSOLENOIDE

precaucion: RECOMENDAMOS ALTAMENTE USAR UN FILTRO DE COMBUSTIBLE DE 75 MICRONES. ESTE DEBE SER COLOCADO EN LINEA ENTRE EL TANQUE Y LA BOMBA DE COMBUSTIBLE.

BOMBADECOMBUSTIBLE808656

MANGUERADEPULSACIÓN

FILTRODECOMBUSTIBLE

SUMINISTRODECOMBUSTIBLEREMOTO

ADITAMENTODEPULSACIÓN

sIsTeMa De esCaPeEltubodesalidohasidocalibradoydiseñadoparafuncionarconlassiguientespartes:A)acopleflexiblede50mmdediá-

metrox57 mmdelongitud(noincluido)

B)moflede“2-tiempos”50/90aprobadoporCIK(nosuministrado)

C)tres(3)resortesdeescape(nosuministrados)

RESORTESDEESCAPE

SOPORTEDEAPOYODELAPARTETRASERADELKART

ACOPLEFLEXIBLE

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fIlTRo De aIRe veRDe• ExisteunadiferenciaentecnologíaconelfiltrodeairedepapelestándaryconsunuevoFiltrodeAireVerdedeAlto

Rendimiento.

• Losfiltrosdepapelatrapanlasuciedadporestarcompuestosdeagujerospequeñosloscualespermitenquepaseelaireperonolasuciedad.Desafortunadamenteestoesmuyrestrictivoparasumotor.Despuésdequecadapartículadesuciedadquedaatrapadaelfiltrosevuelvemuchomásquerestrictivo,hastaqueelflujodeaireatrapacasinada,haciendoquesumotorlehagafaltaaire.Estodisminuyedrásticamenteeldesempeñodesumotor.

• ParaunmejordesempeñoserecomiendaquesuFiltroVerdesealimpiadoeimpregnadodeaceiteentrecadacom-petencia.

• ElFiltroVerdeestácompuestoporalgodóntejidoelcualDEBEserimpregandodeaceite.UnFiltroVerdeatrapalasuciedaddemaneradiferenteaunfiltrodeairedepapel.LosFiltrosdeAireVerdesdeAltoRendimientosondiseña-dosparaserimpregnadosdeaceite.Elaceitecreaunacargamagnéticapositiva(+)conunamalladeaceroinoxid-able,lacualatraelaspartículasdepolvocargadasnegativamente(-).Elpolvoylasuciedadseacumulanalrededordelamallacomoformandountúnel.Estopermitealalgodónpermanecermáslimpioparaunflujomáximodeaire,ycontinuaratrapandolasuciedad.EsteeselporquéestanimportantemantenersuFiltrodeAireVerdeimpregan-dodeaceiteapropiadamente.

• SuFiltroVerdevienepre-impregnadodeaceitedefábrica,perodespuésdecada

• 5-10horasdecompetenciasedeberevisarelfiltro,comprobarquenopresenteobstruccionesysiesnecesariovolveraimpregnarlodeaceite.(Estobasándoseenunascondicionesdecompetencianormales.Silacompetenciaesenunapistasuciaoencondicionesdemuchopolvosedebelimpiarelfiltroconmayorfrecuencia.Paracasosdeextremasuciedadlimpiarcada1-2horasdetiempodecompetencia).

Cleaning instructions:1. Remuevatantasuciedaddelfiltrocomoleseaposiblegolpeándololigeramentesobreunasuperficiedura.

2. UseelKitdeLimpiezayRe-ImpregnacióndeAceitedelFiltroVerde(Parte#2000),rocíeelfiltroconellimpiadorparaFiltroVerde.Dejequelasoluciónempapeelfiltroduranteaproximadamente15minutos.Odiluyaellimpiadorenunbaldeconaguayremojeelfiltro.

3. PRECAUCION::Nuncausedetergentesfuertes,aguaaaltapresiónnigasolina..

4. Enjuageelfiltroconaguatibia,laparteinternaprimeroyluegolaparteexterna.(Dejequeelaguafluyadelladolimpioalladosucio.)

5. Dejequeelfiltrosesequecompletamente.Esmejordejarqueelfiltrosesequenaturalmente.Noutilicecalor,yaqueestepodríaencogerelalgodón.

6. uelvaaimpregnardeaceiteelfiltrousandoUNICAMENTEelaceitedelFiltroVerde(kit#2000).Nouseotrosaceitesparafiltrosdealgodón,elcoloresdiferente(ElaceiteverdeesdecolorverdeyesespecialmenteformuladoparaFiltrosVerdes).

*UstedsabrácuandosehaimpregnadocorrectamentedeaceiteelfiltrosielalgodóncambiadeblancoaVerde.(parecerámojado.)

* PRECAUCION: Asegúrese de no impregnar demasiado su filtro con aceite, ya que puede ocasionar daños en los sensores y en el motor.

Dejequeelfiltrosesequedurante1/2hora.SiustedcolocasuFiltroVerdesobreunpedazodecartóndurante10minu-tosyestedejamanchasdeaceiteustedhaimpregnadodemasiadosufiltroconaceite.Límpieloycomiencedenuevo.

ADVERTENCIA: Nunca use aceite para motor, fluido para transmisión, WD 40. Dejar de seguir las instrucciones puede causar incendios lo que podría ocasionar la muerte, lesiones corporales o daños a la propiedad.

El Kit para Limpieza y Re-Impreganción de Aceite del Filtro Verde es la Parte #2000. Para mayor información y/o preguntas, por favor visite www.greenfilterusa.com

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MonTaJe Del MoToREstemotorestádiseñadoparaserinstaladoENPOSICIÓNHORIZONTALenunkart.Debidoalainstalacióndelcarbura-doryalsistemadelubricación,NOrecomendamosinstalarelmotoraunángulodecualquiergrado.

aCeITe Elaceiteeslavidadetodomotoryusarunodebuenacalidadesundeber!Serecomiendaoperarconnomenosde18onzasdeaceitesintéticogrado30declasificaciónSAE.Esimportantequeelaceiteseacambiadoymonitoreadoregu-larmenteyaquelasuciedadyotroscontaminantestalescomoelcombustible,etc.afectarándesfavorablementelavidadeestemotor.NOTA:ParaelperíododedespeguedesumotoruseUNICAMENTEunaceiteSAEno-sintéticogrado30dealtaclasifi-cación.Elusodeunaceitesintéticoduranteesteprocesopodríaimpedirel“asentamiento”apropiadodelosanillosdelpistón,etc.

DesPeGUe Del MoToR (fUnCIonaMIenTo)Losprimeros30minutosdevidadeestemotorsonlosmásimportantesparagarantizarunacompetenciasinprob-lemas.Despuésdeinstalarelkart,recomendamosqueelmotorseadespegadousandocualquieraceitedealtogradonosintéticogrado30declasificaciónSAE.Opereelmotorsincargaenralenti(1,700-2,000rpm)parapermitirqueelmotoralcancelatemperaturanormaldeoperación(5-8minutos).Apagueelmotorydejequeretornealatemperaturaambiente.Vuelvaadararranquealmotorypermitaquealcancelatemperaturadeoperación(5-8minutos).Apagueelmotorycambieelaceite.Repongaaceite(16-18onzas)yeselmomentodecolocar‘carga’enelmotor.Paraaplicarunacargaenelmotorlaformamásfácilparahacerloesoperarelmotorenlapista.Aunaoperaciónnomásaltade6,000rpm,devariasvueltas(dependiendodelalongituddelrecorrido).Conelaceiteaúncalientedreneycambieelaceite...repitaycomiencelentamenteaqueelmotoralcancevelocidad.

CoMbUsTIble Estemotorhasidodiseñadoparaunabombadegasolinade98Octanos(RON)o93 Octanos(RON+MON/2).Elusodecombustiblesdemásbajooctanajepodríanocasionardetonacióndelmotory/oafectardesfavorablementelavidadesumotor.

MáXIMas RPM ReCoMenDaDasSumotorhasidoequipadoconunsistemadereguladorquelimitarálasRPMdeestemotoraalrededorde7,100RPM+50RPM.Estenoeliminarálanecesidaddetenerunretornoalmecanismoderalentí.Laremociónolamanipulacióndeestesistemapodríaconducirareducirlavidadelmotor,y/oaocasionarlesionesgraves,inclusolamuerte.TampocoserecomiendaelusorepetitivodellimitadorderevolucionescomounfactorlimitativodeRPM.Estelimitadorderevo-lucionestrabajaactivamente“acortando”elsistemadeencendidodesumotor.Ensituacionesrepetitivaspuedepre-sentarsecargaporcombustibleasícomotambiénunincrementoenlacargadepresióninternadelmotor,reduciendoenormementelavidadelmotor.

lIMITaDoR De RevolUCIones – PaRTe #557125

Nodesconectenimodifiqueellimitadorderevolucionesinstalado.Elexcesodevelocidadenelmotorpuededarlugaraunafallaenlavolanteoenotraparteyocasionarlamuerte,lesionesgravesodañosalapropiedad.

adVerTencia

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CaRbURaTeUR WalbRo PZ

Carburateur Walbro PZLecarburateurWalbroPZ26aétéspécialementcalibrépourcetteutilisation.Leguidesuivantdoitvousaiderpourlesréglagesetl’entretien.Lespiècesderechangesontdisponiblesauprèsdevotrefournisseurautorisé.Unjeudegicleurssupplémentairesestaussidisponiblesouslaréf.557012–Cekitaétéspécialementconçupourcouvrirlamajoritédesbesoinsdegicleursàessence.

Hauteur du flotteurLahauteurduflotteurdétermineleniveaudecarburantdanslacuve,cequiinfluesurlesperformancesducarburateur.Réglerlahauteurduflotteurselonlesspécificationsavantd’entreprendretoutautreréglage.

Ralenti, basse vitesseLeréglagedumoteurauralentietàbassevitessesefaitenréglantlavisdemélangederalentiouenchangeantlatailledugicleurderalenti.Latailledugicleurousondiamètreenmillimètresestmarquésurlegicleur(38=troude0,38mm).Lavisdemélangederalentirèglelaquantitédecarburantdelafaçonsuivante:fer-merlavis(latournerdanslesenshoraire)appauvritlemélangeetl’ouvrir(latournerdanslesenscontraire)enrichitlemélange.

Pourréglerlavisdemélangederalenti,procédercommesuit.Fermerlavisdemélangejusqu’àcequ’ellebutelégèrementouqu’ellenepuisseplustourner.Dévisserlavisdunombredetours

spécifié.Fairechaufferlemoteuretréglerlavispourquelerégimederalentisoitunpeuplusélevéqueceluiquevousvoulezobtenir.Unmélangelégèrementtroprichedonnenormalementdemeilleuresaccélérations.

S’iln’estpaspossibled’obtenirunralenticorrectquandlavisdemélangeestdévisséeentre1/4et2toursdepuissapositionfer-mée,ilfautchangerlatailledugicleurderalenti.Unbongicleurderalentipermetuneaccélérationprogressivedepuisleralentijusqu’àunrégimestabilisédumoteurcorrespondantà1/4del’ouverturedel’accélérateur.

Régime intermédiaire, accélérateur en partie ouvertL’aiguilleduboisseaucontrôleprincipalementledébitdecarbu-rantentre1/4et3/4d’ouverturedel’accélérateur.Cetteaiguilledisposedecinqencochesetd’uneagrafeenCàsonextrémitésupérieure.Pourenrichirlemélangequandl’accélérateurestpar-tiellementouvert,déplacerl’agrafepourlamettresurl’encochesuivanteverslebas.Celaéloignel’aiguilledudiffuseur.Pourap-pauvrirlemélangequandl’accélérateurestpartiellementouvert,déplacerl’agrafesurl’encochesuivanteverslehaut.L’encochelaplushaute(lapluséloignéedelapointe)estla1èreposition.L’identificationducônedel’aiguillesefaitgrâceauxlettresderéférencedel’anglesefaitgrâceauxlettresderéférencedel’angledelapointe.

Haut régime, accélérateur à fondLegicleurprincipalcontrôleledébitdecarburantpourunepositiond’accélérateurentreouvertureà1/2etaccélérateuràfond.Latailledugicleurousondiamètreenmillimètresestmarquésurlegicleur.L’altitudeetlesconditionsclimatiquespeuventsuffisammentinfluersurlefonctionnementdumoteurpournécessiterunchangementdetailledugicleurprincipal.Unetempératureélevée,l’humiditéoul’altitudepeuventnécessiterungicleurprincipalpluspetit.Unetempératurebasse,l’humiditéoul’altitudepeuventnécessiterungicleurprincipaldeplusgranddiamètre.

DÉMaRRaGeCecarburateurestéquipéd’unstarterpourledémarrage.Quandlemoteurestfroid,tirerlestarterpourledémarrer.Aufuretàmesureduréchauffementdumoteur,repousserlestarterjusqu’auboutpourunfonctionnementnormal.

ATTENTION: Après avoir raccordé le câble d’accélérateur à la guillotine d’accélération ou CHAQUE FOIS que la guillotine est démontée, déposer le filtre à air et vérifier visuellement que la guillotine se ferme complètement et se déplace sans frottement dans ses coulisses.

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Vis de la cuve 17 – 20 in-lbs

Gicleur de ralenti 9 – 12 in-lbs

Gicleur du boisseau 14 – 16 in-lbs

Gicleur principal 9 – 11 in-lbs

Torque SpecificaTionScoupLeS de SerraGe

Gicleur principal #96

Gicleur de ralenti (Slow Jet) #37

Gicleur du boisseau CDB 4th notch

Diamètre du gicleur principal 2.6 mm

Nombre de tours pour dévisser 1 à 1/2 la vis de mélange de ralenti 1-1/2

Hauteur du flotteur* 14.0 mm

frFrench

Ressort

Coulissed’accélérateur

Kitdegicleurduboisseau

Kitdecâbled’accélérateur

Starter

Visderégimederalenti

Kitdeflotteur

Diffuseurprincipal

Mélangederalenti

Jointdecuvedecarburateur

Pointeaud’admissionetcirclip

Diffuseur

Gicleurderalenti

Gicleurprincipal

Kitdegicleurs(bientôtdisponible)

Kitdecuvedecarburateur

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sCHÉMa ÉleCTRIQUeCesystèmeestconçupourfonctionneràpartird’unesourceélectriquede12volts.Pourlaplupartdesutilisationsencom-pétition,nousrecommandonsd’utiliserunebatterieàgeld’acide,(définieparl’autoritédevérification)d’aumoins8Ahdecapacité.Uncâblepositifdebatteriede8mm2estnécessairepourraccorderlabatterieaudémarreur.Lecontacteuràbascule,Réf.557028,situésurlecapotmoteurenplastique,Réf.555699,per-metdecouperlecontact.

Voirlecontacteurdedémarrageetlesraccordementsdelabatteriedansleschémadecâblagedudémarreur.

PoMPe D’alIMenTaTIonLeschémasuivantdonneladispositionrecommandéepourraccorderlapompeàessenceaumoteurdecourseWorldFormula.UnepompeàessenceMikuniestfournieaveclemoteur.Lapompedoitêtreinstalléeselonlesrecom-mandationsdevotreorganisationCIKlocale.Nousrecommandonsdeplacercettepompeàessenceàunendroitoùelleneserapasaffectéeparlachaleur.LalignederefoulementestindiquéeparunPsurlapompe.CettesortiedoitêtreraccordéeparuneDurit(spécialementfabriquéepourutilisationavecdel’essence)auraccordsurledessusducollecteurd’admission.Lesdeuxautresrac-cordsdelapompeontdesflèchesquiindiquentl’entréeetlasortiedelapompe.Veuillezvousréférerauschémajoint.

Schéma de câblage du démarreur électrique

CONTACTEURDUDÉMARREUR

VERSLESUPPORTDEMONTAGEDUMOTEUR

BATTERIE12V

DÉMARREURETSOLÉNOÏDE

aTTenTion: NOUS RECOMMANDONS FORTEMENT D’UTILISER UN FILTRE À ESSENCE DE 75 MICRONS ET DE LE METTRE EN LIGNE ENTRE LE RÉSERVOIR ET LA POMPE À ESSENCE.

POMPED’ALIMENTATION808656

DURITDEPRISEDEDÉPRESSION

FILTREÀCARBURANT

ALIMENTATIOND’ESSENCEÀDISTANCE

RACCORDDEPRISEDEDÉPRESSION

sYsTèMe D’ÉCHaPPeMenT Letuyauducollecteuraétéconçuetmisaupointpourfonctionneraveclespiècessuivantes:A)Unraccordflexiblede50mm

dediamètreet57mmdelong(nonfourni)

B)Unsilencieux«2temps»de50/90approuvéparlaCIK(nonfourni)

C)Trois(3)ressortsd’échappement(nonfournis)

RESSORTS D’ÉCHAPPEMENT

SUPPORT ARRIÈRE DU KART

RACCORD FLEXIBLE

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les fIlTRes veRTs• IlyaunegrandedifférencedetechniqueentreunfiltreàairstandardenpapieretvotrenouveauFiltreVerthaute

performance.

• Lespetitstrousdesfiltresenpapierarrêtentlapoussièreetlaissentpasserl’air.Malheureusement,ilsrestreignentbeaucouplescapacitésdumoteur.Chaqueparticuledepoussièrearrêtéeboucheunpeupluslefiltrejusqu’àcequeledébitd’airdeviennetrèsfaible,empêchantlemoteurderespirer.Ceciréduitconsidérablementlesperformancesdumoteur.

• Pourconserverlesperformancesaumeilleurniveau,ilestrecommandédenettoyeretd’huilerleFiltreVertentrechaquecourse.

• LeFiltreVertestfaitdecotontisséquiDOITêtrehuilé.Iln’arrêtepaslapoussièrecommeunfiltreenpapier.LesFiltresVertshauteperformancesontconçuspourêtrehuilés.L’huilecréeunechargemagnétiquepositive(+)aveclagrilleenacierinoxydablequiattirelesparticulesdepoussièrechargéesnégativement(-).Lapoussièreetlasaletéseconcentrentautourdelagrillepourformeruntunnel.Celapermetaucotonderesterpluspropreetdelaisserpasserundébitd’airmaximum,toutenarrêtantlapoussière.C’estpourquoiilestimportantdetoujourshuilercor-rectementleFiltreVert.

• VotreFiltreVertaétéhuiléenusine,maisilfautvérifiersonencrassementtoutesles5à10heuresdecourseetl’huilerdenouveau.(Celatientcomptedesconditionsnormalesdecourse.Lorsquel’oncourtsurterreoudansdesconditionspoussiéreuses,ilfautnettoyerlefiltreplussouvent.Danslescasextrêmes,ilfautlenettoyertoutesles1à2heuresdecourse).

Instructions de nettoyage :1. Retirerautantdepoussièrequepossibleentapantlefiltresurunesurfacedure.

2. Aveclekitdenettoyageetd’huilageduFiltreVert(Réf.2000),vaporiserlefiltredenettoyant.Laisserlasolutions’imprégnerdanslefiltrependant15minutesenviron.Oudiluerlenettoyantdansunbaquetd’eauetlaissertremper.

3. ATTENTION:Nejamaisutiliserdedétergentpuissant,d’eausouspressionnid’essence.

4. Rincerlefiltreàl’eauchaude,del’intérieurversl’extérieur.(Laisserl’eaucoulerducôtépropreverslecôtésale.)

5. 4.Laisserlefiltreséchercomplètement.Ilvautmieuxlelaisserséchernaturellement.Nepaslechauffer,celapour-raitfairerétrécirlecoton.

6. 5.HuilerlefiltreUNIQUEMENTavecl’huilepourFiltreVert(kitRéf.2000).Nepasutiliserd’autreshuilespourfiltreencoton,lacouleurestdifférente(L’huileverteestcoloréeenvertetestspécialementformuléepourlesFiltresVerts).

*Unfiltreestcorrectementhuilélorsquelecotonblancprendunecouleurverte(lefiltreparaîthumide)

* ATTENTION: S’assurer de ne pas mettre trop d’huile sur le filtre, cela peut endommager les capteurs et le moteur.

Laisserlefiltresécherpendant1/2heure.SionlaisseleFiltreVertsurunmorceaudecartonpendant10minutesetqu’ilylaissedestachesd’huile,c’estqu’ilesttrophuilé.Lenettoyeretrecommencer.

AVERTISSEMENT : Ne jamais utiliser de l’huile de transmission, WD 40. Le fait de ne pas re-specter les instructions peut entraîner un incendie qui peut provoquer la mort, des blessures corporelles ou des dégâts matériels.

La référence du kit de nettoyage et d’huilage du Filtre Vert est 2000. Pour obtenir plus d’informations et les réponses à vos questions, visiter le site : www.greenfilterusa.com.

MonTaGe DU MoTeURCemoteuraétéconçupourêtremontéàPLATdanslekart.Enraisondesréglagesetdusystèmedegraissageducar-burateur,nousNErecommandonsPASdemonterlemoteurselonunanglequelconque.

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HUIle L’huileestlasurviedetoutmoteuretilestabsolumentnécessaired’utiliserunehuiledebonnequalité.Nousrecom-mandonsd’utiliseraumoins0,5l(18onces)d’huilesynthétiqueSEA30.Ilestimportantdechangeretdesurveillerl’huiledefaçonrégulièrecarlapoussièreetd’autrescontaminations(essence,etc.)affectentladuréedeviedecemoteur.

NOTE:Pendantlerodagedumoteur,n’utiliserQUEdel’huilenonsynthétiqueSAE30debonnequalité.L’utilisationd’unehuilesynthétiquependantlerodagepourraitempêcherlebon«rodage»dessegments,etc.

RoDaGe DU MoTeURLestrentepremièresminutesdelaviedecemoteursontlesplusimportantespoursonavenirencourse.Aprèsl’avoirmontésurlekart,nousrecommandonsderoderlemoteuravecunehuilenonsynthétiqueSAE30debonnequalité.Fairetournerlemoteur,àvide,auralenti(1700à2000tr/mn)etlelaisseratteindresatempératurenormaledefonc-tionnement(5à8minutes).Arrêterlemoteuretlelaisserrefroidiràlatempératureambiante.

Ledémarrerdenouveauetl’ameneràsatempératuredefonctionnement(5à8minutes).L’arrêteretchangerl’huile.Remplird’huileneuve0,5à0,6l(16à18onces)etcommenceràlemettreen«charge».Pourlemettreencharge,lameilleuresolutionestdel’utilisersurlapiste.Nepaslefairetourneràplusde6000tr/mn,faireplusieurstours(selonlalongueurdelapiste).Pendantquelemoteurestencorechaud,vidangeretremplacerl’huile.Recommenceretcom-mencerlentementàmonterlesrégimes.

essenCe Cemoteuraétéconçupourfonctionneravecdel’essenceducommerceà98Octane(RON)ou93OctaneRON+MON/2).L’utilisationd’unindiced’octaneplusfaiblepeutentraînerunedétériorationdumoteuretinfluersurladuréedeviedumoteur.

RÉGIMe MaXIMUM ReCoMManDÉCemoteurestéquipéd’unsystèmederégulateurquilimitelerégimeàenviron7100tr/min+50tr/min.Celan’empêchepasd’avoirunmécanismederetourauralenti.Ladéposeouunemodificationdecesystèmepeutréduireladuréedeviedumoteuretunrisquedeblessuregrave,voiremêmelamort.Nousnerecommandonsdoncpasd’utiliserenpermanencelelimiteurderégimecommemoyend’atteindrelerégimemaximum.Celimiteurderégimefonctionneen«coupant»lesystèmed’allumagedumoteur.L’utilisationrépétitiveàpleingazainsiquedestensionsinternes,ac-croissentlachargedumoteuretréduisentfortementsaduréedevie.

lIMITeUR De RÉGIMe, RÉf. #557125

Nepasdébranchernimodifierlelimiteurderégimeinstallé.Unsurrégimepeutentraînerunedéfaillanceduvolantmoteuroud’autrespièces,entraînantlamort,desblessuresgravesoudesdégâtsmatériels.

aTTenTion

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DaTe WoRk PeRfoRMeD seal nUMbeR WoRk PeRfoRMeD bY

1/31/08 example: Replaced Air Cleaner DK

log book

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