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TILLOTSON T4 User Manual
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TILLOTSON T4 User Manual

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Tillotson T4 User Manual

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Summary of Contents for TILLOTSON T4

  • Page 1 Tillotson T4 User Manual...
  • Page 2 Introduction: Congratulations on purchasing a Tillotson T4 Kart package! This document has been prepared to offer information on all items from building the new kart to maximising the performance from the equipment. It will advise on many aspects including the following: ...
  • Page 3 Loctite Steps to Take: Take all items from the T4 packaging and identify each item supplied It is recommended to start by fitting the axle first. Mount the Rear Axle fitting the Sprocket Carrier and Brake Disc in Correct position and ensure the axle is fitted the correct orientation so the keyway lines up to the brake disc / sprocket carrier and not in reverse.
  • Page 4 Mount Clutch using impact gun or with a 13mm socket with a spark plug stopper so to tighten the clutch sufficiently. Mount the inlet Manifold. USE LOCTITE ON BOTH STUDS. Mount Tillotson HW Carburettor: check Jet Settings using the Tillotson Quickjet tool. L: 2T H: 1T...
  • Page 5 Ensure the overflow bottle from the fuel tank has a hole drilled to vent the fuel tank. Mount Tyres Fit the Tillotson Racing Decals to the T4 Kart using heat gun if necessary to soften the material Double check each nut and bolt is tight Fill with Fuel Proceed to Running-in Procedure for the Engine.
  • Page 6 Drain the oil when hot so it can easily transport any particles. Re-fill 500mL of Tillotson Racing oil into the engine and you are race ready.
  • Page 7 The chassis has been designed specifically to suit the Tillotson 225RS engine with user friendliness in mind and to provide great handling performance. Only stock components will be allowed in the T4 Series in order to maintain the low cost for the category including Seat, Axle, Wheels, etc.
  • Page 8 From Front Chassis Rail to Front Of Seat RHS: 58-66cm Tyres Pressures: Maxxis Sport T4 Slicks: This tyre is a medium compound which is extremely durable. The recommended window for this tyre is from 12Psi – 18Psi. The occasion to run lower tyre pressures would be in very hot track conditions or for a very long race so the tyre will not drop off a lot during the race.
  • Page 9 Damp: 10-12Psi Wet: 12-16Psi Heavy Rain: 16-20Psi Stock Recommended T4 Kart Setup Front Width: 10mm Caster / Camber: Neutral Front Chassis Height: Middle (Neutral) Steering Track Rod Position on Steering Column: Middle Rear Width: 139cm – 140cm Rear Chassis Height: Middle (Neutral)

  • Page 10: Engine Specification

    TPP225RS Engine: Engine Specification Feature: Specification Engine Tillotson 225RS, 2 Valve, 4 Stroke, Single Cylinder Fuel Type Unleaded Petrol Bore x Stroke (mm) 72 x 56mm Displacement (cc) 225cc Required Oil Capacity Min 500mL Oil Type Tillotson Racing Oil by (*only oil XERAMIC®...

  • Page 11: Torque Values

    Engine Recommendations: Description Recommendation Replace Engine Oil Immediately after Running-in engine / otherwise required after 5hrs of running. Ignition Coil – Flywheel Gap 0.75mm Valve Clearance Gap 0.15mm Carburettor Recommend Settings L: 2T +/- 5mins H: 1T Carburettor Pop-Off Pressure Opening: 0.75Bar Closing: 0.55Bar Using standard pop-off spring 37g...
  • Page 12 Tillotson Racing Oils / Lubricants: Tillotson have partnered with XERAMIC® Kart Lubricants to develop a specific oil to offer long engine life and optimum lubrication. The oil is also unique which can detect any contamination or additives to the oil by a method of inspecting with a UV lamp which has been developed to cut out cheating.
  • Page 13 (Full including inlet needle and seat) – if it is sealing well, it is necessary to fit a DG kit only however if it is leaking or not sealing, it is advised to fit a repair kit. For the T4 kart is...
  • Page 14  Remove the carb top and fuel filter gauze – below there are some dirt particles present which must be blown out with compressed air or carb cleaner.  Remove the 6 Torx screws to dismantle the metering and fuel pump covers from the main body.
  • Page 15  Spray the area with carb cleaner and blow out with compressed air – make sure no dirt particles pass into the inlet needle and seat area as this can cause the carb to leak. If your carburettor is not sealing: ...
  • Page 16  With your inlet seat tool, remove the seat and copper washer underneath.  Blow out with carb cleaner and compressed air in the inlet seat orifice.
  • Page 17 Fit the new inlet seat and re-assemble with the new inlet needle.  Using an adaptor piece (Tillotson p.n. 243-506P) it is possible to check if the carb is now sealing in the needle and seat before assembling fully. ...
  • Page 18  When the fuel cap is tight re-check the pop-off pressure to confirm it is sealing well.  Re-set the carb setting to your ‘home’ position; we recommend using the QuickJet tool as it allows the user to be very precise and ensures repeatability with the setting of both high and low speed jets.
  • Page 19  For a complete overhaul of the carburettor it is advisable to also remove both low and high speed jets.  Remove the rubber O Ring inside the orifice and inspect to see if there is damage – replace if necessary.
  • Page 20 Things Not To Do To When Maintaining the Carburettor: It is equally as important to know also the things ‘Not To Do’ when maintaining the carburetor as damage to the body can hinder performance or even damage it beyond repair! ...
  • Page 21 This will also improve the reliability of the engine! To see a video of how to rebuild your Tillotson carburetor visit the Tutorial on Youtube: https://youtu.be/AsendO9vQvU...
  • Page 22 Kart Preparation: After each day of driving it is necessary to carry out various checks to be sure the kart is ready for the next day out: Carry out a spanner check on the go kart and engine bolts (especially if driving on a rough or bumpy circuit) Clean the kart –...
  • Page 23 Necessary Tools for Race Event: Spanners / Wrench Sizes: 8mm, 10mm, 13mm, 16mm, 17mm Socket Sizes: 8mm, 10mm (x 2), 13mm (x 2), 17mm, 22mm Allen Key Set: 2.5mm, 3mm, 4mm, 5mm, 6mm, 7mm, 8mm Measuring Tape Snips / Pliers Straight Edge Ruler / Laser Sprocket Aligner: For setting the position of sprocket so chain is aligned Fuel Can / Fuel Funnel Loctite...
  • Page 24 Enter the event registration on-time Ensure kart is conforming to the T4 Rules and Regulations set so it will pass Technical Scrutineering Ensure you have ordered race tyres in advance of the event with the tyre supplier Ensure you sign on for the event when arriving to the circuit Ensure you receive safety scrutineering at the allocated time Once you have completed these steps you are ready for T4 competition…...
  • Page 25 Troubleshooting: Engine will not Start: 1. Check the condition of the spark plug if not changed in long time the plug will be full of carbon and may need to be cleaned / replaced. 2. Check the pop-off pressure of the carburettor. It should be sealing at a minimum of 0.45bar if less than this it is necessary to fit a new needle and seat kit (pn233-721P).