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! 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
The authoritative manual
in case of discrepancy is the
manual on the website
www.swissauto.com
control.
31
swissauto
swissauto
swissauto
swissauto
EVO2
Assembly Instructions
and
Operating Manual
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Summary of Contents for Swissauto 250
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Page 1: Assembly Instructions
! IMPORTANT NOTICE! This engine is designed strictly for competition purposes only. The manufacturer SWISSAUTO declare that all spare parts and EVO2 engines are not covered by any warranty. Only SWISSAUTO can recognize the manufactured defect after control. - Page 2 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: Buchmattstrasse 46 - 48 3400 Burgdorf Schweiz www.swissauto.com Scope of Supply Customer’s name Installation onto the Go-Kart Start-up Maintenance...
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Page 3: Technical Data
4 valves per cylinder, DOHC on roller bearings Crankshaft Steel, forged, roller bearings Piston Aluminium forged ● engine ‚swissauto 250’ with clutch, ignition and fuel pump ● radiator Connecting rod Steel, forged, mounted on roller bearings ● radiator support with silent blocks, bolts and nuts ●... - Page 4 Installation onto the Go-Kart Table Tightening Torque Tightening Torque Thread Strenght Complete the engine by assembling the ignition coil, the radiator Step 1: and the carburetor. Charge the battery! Loctite Engine mount allen screw Transmission sprocket bolt hexagon with flange Transmission sprocket nut hexagon M28x1...
- Page 5 Table Gear Ratios Installation onto the Go-Kart Top Speed at 13'000 rpm Transmission Rear Transmission Rear Bolt M8x80 with washer sprocket sprocket Top Speed [km/h] sprocket sprocket Top Speed [km/h] 83.9 109.2 84.8 110.2 85.8 110.5 Self-locking flange nut M8 86.8 111.5 87.8...
- Page 6 Installation onto the Go-Kart Table Main Jets Height above sea level >1000 Hose clamp 28.6 900 910 920 930 940 950 960 970 980 990 1000 1010 1020 1030 air pressure [mbar] Cooler hose below 104 104 106 106 106 106 108 108 108 108 104 104 104 106 106 106 108 108 108 108 104 104 104 106 106 106 106 108 108 108 Hose clamp 27.1...
- Page 7 Basic Settings of the Carburetor Installation onto the Go-Kart Carburetor Dell’orto PHF 30 DD1 Put the two hose clamps onto the Main jet carburetor rubber and push the rubber onto the intake port. Idle jet Inner venturi Needle jet AB 260 Put the carburetor into the Needle carburetor rubber and tighten...
- Page 8 Installation onto the Go-Kart Electrical schematic Position the engine onto the go-kart. Step 2: Put the primary tube gasket into the primary tube port. Install the primary tube loose with 2 flange nuts M6 in order to be able to position the primary tube. Position the primary tube in that way to leave a gap of 1mm.
- Page 9 Assembling the Clutch Installation onto the Go-Kart Lock the clutch with the special tool “BATMAN” The distance between primary tube and driver seat should result in Install the clutch onto the min. 2cm. crankshaft (do not forget the key). Degrease the cone. In case that the primary tube is too close to the seat or if you like a different engine position compared...
- Page 10 Installation onto the Go-Kart Changing the Clutch Install the battery box. Step 3: Install the control unit onto the two silent blocks and tighten both flange nuts M6. Remove all bolts on the back of Lead the cables behind the control the starter sprocket.
- Page 11 Dismantling the Clutch Installation onto the Go-Kart Wiring Step 4: Dismantle the generator stator Connect the plus and the minus cable Loosen the transmission sprocket on the battery with the provided slot bolt. nuts and bolts. Remove the clutch drum and the sprocket bearing.
- Page 12 ● For a fast change of the gear ratio we recommend an additional clutch drum with a pre-mounted transmission sprocket. 2 Ignition ON (Position during driving) ● All manuals and spare parts lists can be found on our homepage: 3 Run starter motor www.swissauto.com...
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Page 13: Recommended Accessories
Recommended Accessories Installation onto the Go-Kart These accessories are not included in the scope of supply. Install the exhaust silencer Step 5: Torque absorber Install the exhaust silencer on a commercially available exhaust The torque absorber is a sprocket bracket (not included in the scope mount on the rear axle, which of supply). -
Page 14: Special Tools
Installation onto the Go-Kart Special Tools Install the throttle cable. Step 7: We recommend the following special tools: ● Clutch puller ● Clutch stop tool „BATMAN“ ● Leaf metal ignition 1.2mm Install the inner wire of the throttle ● Sprocket key Z13 cable on the carburetor and lead the wire with the cable sleeve With these special tools the clutch and the transmission sprocket on the clutch... - Page 15 Pull the choke lever on the carburetor and press the start button. Let the engine run for 10 seconds. Then switch it off and check the oil level. www.swissauto.com The oil level should be now at or just slightly above the middle of the oil show glass.
- Page 16 Start-up Maintenance The maintenance of the ’’swissauto 250 engine’’ is substantial for its service life. If too much oil is present in the engine, the engine might eject the excessive oil by If maintenance is carried out incorrectly or insufficiently the service life might be the crankcase ventilation hose into the air filter.
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