TPK-400GS - Gardner, Inc.

Illustr
ated P
ar
ts Man
ual
Illustra
Par
arts
Manual
Model Number:
TPK-400GS
40cc Paveracer Kart
P/N 32220
Rev 000
Date 3-13-04
Supplier To The Outdoor Power Equipment Industry
ISM, Inc. • 1028 4 Street SW • Auburn, WA 98001 • Phone: (253) 333-1200 • Fax: (253) 333-1212
th
www.tanaka-usa.com
[email protected]
PARTS INFORMATION
TPK-400GS
HANDLE & CONTROLS • FIGURE 1
ITEM
1-1
1-2
1-2-1
1-2-2
1-3
1-3-2
1-4
1-5
1-6
1-6-1
1-13
1-25
1-26
1-31
1-44
1-68
1-83
1-84
1-86
PART NUMBER
30798
70079
30801
70023
70024
70026
70027
70028 BK
70029
70078
70041
70051
70052
70055
70066
70068
70076
30830
31566
www.tanaka-usa.com
DESCRIPTION
GRIP,HANDLE
LEVER,BRAKE ASS'Y
LEVER,BRAKE
CABLE,BRAKE,TPK
LEVER,THROTTLE ASSY,TPK
CABLE,THROTTLE,TPK
HANDLEBAR,TPK
FRAME,BLACK,TPK
HANDLEBAR STEM
HANDLEBAR STEM CAP
TIE ROD,LONG
HANDLEBAR NYLON
PLASTIC,GM2518
SWITCH,TOGGLE,TPK
PLATE,SWITCH
CABLE END,THROTTLE
WASHER
WASHER,SPRING M6
BOLT,M6xP1.0x15
Page 1
QTY
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
COMMENTS
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PARTS INFORMATION
TPK-400GS
HEAD BEARING KIT & STEERING • FIGURE 2
ITEM
2-6
2-7-1
2-8
2-9
2-10
2-11
2-12
PART NUMBER
70029
70030
70038
31563
70039
30936
70040
www.tanaka-usa.com
DESCRIPTION
HANDLEBAR STEM
HEAD BEARING KIT
STEERING STEM
BOLT,M6xP1.0x20
TIE ROD END
NUT,M6xP1.0
TIE ROD,SHORT
Page 2
QTY
1
1
1
1
1
3
1
COMMENTS
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PARTS INFORMATION
TPK-400GS
FRONT WHEELS • FIGURE 3
ITEM
3-10
3-11
3-13
3-14
3-15
3-16
3-18
3-19
3-20
3-21
3-22
3-23
3-69
3-72
3-89
3-90
PART NUMBER
70039
30936
70041
70042
70043
70044
70045
70046
70047
70048
31795
70050
70069
30936
31468
31428
www.tanaka-usa.com
DESCRIPTION
TIE ROD END
NUT,M6xP1.0
TIE ROD,LONG
SPACER,T-1174
WHEEL MOUNT,RIGHT
BOLT,K-292
WASHER
NUT
WHEEL BEARING,FRONT,TPK
SPACER,T-1172
FRONT WHEEL SET,STOCK
WASHER
WHEEL MOUNT,LEFT
NUT,M6xP1.0
BOLT,M6xP1.0x25
BOLT,M6xP1.0x30
Page 3
QTY
COMMENTS
3
7
1
3
1
2
2
2
4
2
1 NOTE: Wheel bearings not included
2
1
2
2
2
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PARTS INFORMATION
TPK-400GS
BRAKE CALIPER AND BRAKE PADS • FIGURE 4
ITEM
4-11
4-23
4-24
4-41
4-42
4-43
4-46
4-47
PART NUMBER
30936
70050
30830
70065
31150
31212
70067
70090
www.tanaka-usa.com
DESCRIPTION
NUT,M6xP1.0
WASHER
WASHER,SPRING M6
BRAKE CALIPER ASSY
BOLT,M6xP1.0x35,RD HD
SPACER,T-849
WHEEL BEARING,REAR,TPK
BRAKE PAD SET
Page 4
QTY
COMMENTS
2
2
2
1 Includes brake pads
2
2
2
1
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PARTS INFORMATION
TPK-400GS
SEAT & SEAT HARDWARE • FIGURE 5
ITEM
5-11
5-29
5-30
5-43
5-45
5-82
5-83
PART NUMBER
30936
70054
31468
31212
31563
30936
70076
www.tanaka-usa.com
DESCRIPTION
NUT,M6xP1.0
KART SEAT
BOLT,M6xP1.0x25
SPACER,T-849
BOLT,M6xP1.0x20
NUT,M6xP1.0
WASHER
Page 5
QTY
4
1
4
1
2
4
4
COMMENTS
[email protected]
PARTS INFORMATION
TPK-400GS
REAR AXLE, REAR WHEELS, BRAKE ROTOR & AXLE SPROCKET • FIGURE 6
Alternative Axle Sprockets
32085 AXLE SPROCKET,31TH (-1)
32087 AXLE SPROCKET,33TH (+1)
ITEM
6-11
6-32
6-33
6-34
6-35
6-36
6-37
6-38
6-39
6-40
6-46
6-91
PART NUMBER
30936
70056
70057
70058
31796
70060
70061
32086
70063
70064
70067
70077
www.tanaka-usa.com
DESCRIPTION
NUT,M6xP1.0
AXLE,REAR WHEEL
WASHER
NUT
REAR WHEEL SET,STOCK
BOLT,K-295
SPACER,T-1139
AXLE SPROCKET,32
KEY,6x6x28
BRAKE ROTOR
WHEEL BEARING,REAR,TPK
BOLT,K-289A
Page 6
QTY
3
1
2
2
1
1
2
1
1
1
2
2
COMMENTS
[email protected]
PARTS INFORMATION
TPK-400GS
REAR BUMPER, ROLLERS & FLAG • FIGURE 7
ITEM
7-74
7-75
7-77
7-80
7-81
7-83
7-84
7-85
7-86
PART NUMBER
70071
70072
70073
70074
70075
70076
30830
30821
31566
www.tanaka-usa.com
DESCRIPTION
REAR BUMPER
FLAG,G01-002
BUMPER CUSHION
ROLLER WHEEL
WASHER
WASHER
WASHER,SPRING M6
NUT,M8xP1.25
BOLT,M6xP1.0x15
Page 7
QTY
1
1
1
2
4
3
3
4
3
COMMENTS
[email protected]
PARTS INFORMATION
TPK-400GS
ENGINE COVER & CHAIN GUARD • FIGURE 8
ITEM
8-28
8-59
8-70
8-82
8-83
8-86
PART NUMBER
70053
31097
70070
30936
70076
31566
www.tanaka-usa.com
DESCRIPTION
SPROCKET COVER
BOLT,M6xP1.0x10
ENGINE COVER
NUT,M6xP1.0
WASHER
BOLT,M6xP1.0x15
Page 8
QTY
1
4
1
1
5
5
COMMENTS
[email protected]
PARTS INFORMATION
TPK-400GS
GEAR BOX, CLUTCH DRUM & CHAIN • FIGURE 9
Alternative Counter Sprockets
32088 COUNTER SPROCKET,16 TH (-1)
32090 COUNTER SPROCKET,18 TH (+1)
ITEM
9-11
9-23
9-24
9-45
9-47
9-48
9-49
9-50
9-53
9-55
9-62
9-63
9-65
9-65
9-65
9-65
9-66
9-66
9-66
PART NUMBER
30936
31197
30830
70081
70082
70083
30836
70084
32089
30821
70086
70087
PF-3300
TC-355
PF-4000
TC-4700
32200
32228
32229
www.tanaka-usa.com
DESCRIPTION
NUT,M6xP1.0
WASHER
WASHER,SPRING M6
BOLT
HOUSING,ENGINE MOUNTING
BOLT,M6xP1.0x30
DRUM,CLUTCH
GEAR BOX
COUNTER SPROCKET,17
NUT,M8xP1.25
BOLT
BOLT
PureFire Engine,33cc
Engine,35cc
PureFire Engine,40cc
Engine,47cc
CHAIN,TPK
CHAIN,10FT BOX,TPK
CHAIN,100FT ROLL,TPK
Page 9
QTY
COMMENTS
5
3
7
2
1
3
1
1
1
1
1
3
1
1
1
1
1
Opt Includes master links. Makes 5 loops
Opt
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PARTS INFORMATION
PF- 4000
CYLINDER, PISTON, IGNITION • FIGURE 1
ITEM
1-5
1-6
1-8
1-11
1-12
1-14
1-15
1-16
1-17
1-18
1-21
1-22
1-31
1-44
1-45
1-46
1-50
1-56
1-56
1-59
1-63
PART NUMBER
25504200200
15711666900
01804075200
0010440590
99461050204
0170440020
04104050200
0300440090
0370100020
03905004200
0460440080
99962101004
06802000200
56020517200
1782054320
1672054390
1790007080
99011040182
99416040183
1820186A201
19805015800
DESCRIPTION
COVER,SPARK PLUG,RUBBER
CAP,SPARK PLUG ASS'Y
PLUG,SPARK
SET,CYLINDER
BOLT,HEX,HOLE,5X20,S
GASKET,CYLINDER
RING,PISTON
SET,PISTON
PIN,PISTON
CIRCLIP,PISTON PIN
CRANKSHAFT
BEARING,NEEDLE,F1010B
KEY,WOODRUFF,3X13X5
CAP,RUBBER
CORD,HIGH TENSION
ASSY,IGNITION COIL
STOP CORD,220MM
SCREW,4X18
SCREW 4X18/WS
WASHER,SPECIAL
CLAMP,CORD
www.tanakapowerequipment.com
Page 10
QTY
COMMENTS
1
1
1
1
4
1
2
1
1
2
1
1
1
1
1
1
2
2 Before S/N U112140
2 S/N U112141 and after
2
1
[email protected]
PARTS INFORMATION
PF- 4000
CRANKCASE, FLYWHEEL, STARTER PULLEY • FIGURE 2
www.tanakapowerequipment.com
Page 11
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PARTS INFORMATION
PF- 4000
CRANKCASE, FLYWHEEL, STARTER PULLEY • FIGURE 2
ITEM
2-9
2-19
2-20
2-23
2-24
2-25
2-26
2-26
2-27
2-28
2-29
2-32
2-32
2-32
2-32
2-32
2-36
2-51
2-52
2-54
2-55
2-60
2-66
2-66
2-67
2-69
PART NUMBER
99463050204
7880162V20
99355050000
99111100013
7900162V200
7980422090
0720440090
0720440091
0900440020
99966152511
99961620200
07102007200
07102007210
07102007220
07111600230
07111600240
99461050304
1552053880
99201100011
99101100011
99414050101
1320440020
1120440021
1120441321
99461050204
20311660200
DESCRIPTION
BOLT, HEX 5X20
PAWL,STARTER
RING,STOP,5
NUT,10
SPRING,PAWL,STARTER
PAWL,STARTER ASS'Y
CASE,CRANK
CASE,CRANK
GASKET,CRANKCASE
SEAL,OIL,#VE15X25X7
BEARING,BALL,#6202
SHIM,15.2X20X.05
SHIM,15.2X20X.10
SHIM,15.2X20X.15
SHIM,16X21X.20
SHIM,16X21X.30
BOLT,HEX,5X30S
ROTOR,MAGNETO
WASHER,10
NUT,10
SCREW,S,5X10
DEFLECTOR,AIR
CASE,FAN (ORANGE)
CASE,FAN (POLISHED)
BOLT,HEX,HOLE,5X20,S
GROMMET,PRIMARY CORD
www.tanakapowerequipment.com
QTY
1
1
1
1
1
1
1
1
1
2
2
V
V
V
V
V
4
1
1
1
1
1
1
1
4
1
Page 12
COMMENTS
Before S/N U207704
S/N U207705 and after
*Crankcase assy includes bearings, seals
and gaskets.
*Shims are "as needed" to obtain
correct side clearance
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PARTS INFORMATION
PF- 4000
MUFFLER, MUFFLER COVER • FIGURE 3
86
ITEM
3-1
3-3
3-4
3-5
3-6
3-7
3-8
3-8
3-10
3-11
3-13
3-14
3-16
3-23
3-23
3-24
3-25
3-26
3-81
3-82
3-83
3-84
3-85
3-86
PART NUMBER
7380440A21
99461050124
99461050164
99053060653
99201060011
7040440090
99201050061
99201050061
7210440020
99434040081
7320440020
73704230200
1330440020
99463050204
99463050204
2030604A202
99461050254
99201050061
35910112203
2900420081
34204200200
99204100030
35704201200
30790
DESCRIPTION
PROTECTOR,MUFFLER
BOLT,HEX,5X12S
BOLT,HEX,5X16,S
SCREW,HEX,6X65
WASHER,6
SET,MUFFLER
WASHER,5
WASHER,5
PIPE,TAIL
SCREW,4X8/S
ARRESTER,SPARK
GASKET,MUFFLER
SHIELD,HEAT
BOLT, HEX 5X20
BOLT, HEX 5X20
GROMMET
BOLT,HEX HOLE,5X25S
WASHER,5
WASHER,CLUTCH B
SHOE,CLUTCH
SPRING,CLUTCH
WASHER,WAVE,10
BOLT,CLUTCH STEP
CLUTCH ASS'Y
N/A
N/A
N/A
N/A
N/A
32014
32015
32016
32017
32018
SPRING,POWER PIPE,SHORT
SPRING,POWER PIPE,LONG
SPACER,POWER PIPE
SCREW,POWER PIPE
WASHER,POWER PIPE
www.tanakapowerequipment.com
QTY
1
1
1
2
2
1
2
1
1
1
1
1
1
4
2
1
2
2
2
2
1
2
2
1
Page 13
1
2
2
4
4
COMMENTS
Before S/N U207704
Before S/N U207704
S/N U207705 and after
Before S/N U207704
S/N U207705 and after
S/N U207705 and after
S/N U207705 and after
Power pipe hardware, not shown
Power pipe hardware, not shown
Power pipe hardware, not shown
Power pipe hardware, not shown
Power pipe hardware, not shown
[email protected]
PARTS INFORMATION
PF- 4000
FUEL SYSTEM, AIR FILTER • FIGURE 4
#32225 HP Velocity Stack / Air Filter
Upright design suspends fuel better thus
improves overall engine performance.
Includes choke plate.
Shown on TC-47 engine.
www.tanakapowerequipment.com
Page 14
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PARTS INFORMATION
PF- 4000
FUEL SYSTEM, AIR FILTER • FIGURE 4
ITEM
4-31
4-32
4-33
4-34
4-35
4-36
4-37
4-38
4-39
4-40
4-41
4-42
4-43
4-44
4-45
4-46
4-49
4-62
4-63
4-64
4-65
4-66
4-66
4-68
4-70
4-73
4-74
4-75
4-76
4-76
4-77
4-78
4-79
4-80
4-86
4-87
4-88
PART NUMBER
4030430020
4040430090
4020430020
4530637C200
4700138020
4230138082
5280138021
47601700200
4460138020
99204080030
4520138091
3800637C200
99011050602
99210050012
4550440090
78600601200
99416050253
6490168020
22301251901
68000731201
67501630900
5910440021
5910441321
6590430020
5950656B90
6463252L90
5650440020
5640661190
99463050204
99463050204
9400430020
70003005100
68000206200
22206300200
99461050304
99201050061
6420608A200
DESCRIPTION
GASKET,INLET MANIFOLD
SET,CARB INSULATOR
GASKET,CARBURETOR
COLLAR
COLLAR,CLEANER
BODY,CLEANER
VALVE,CHOKE
BOARD,BLOW OVER CHECK
ELEMENT,CLEANER
WASHER,8
COVER,CLEANER,ASSY
BOLT,CLEANER COVER
SCREW,5X60
WASHER,S,5
CARBURETOR
WASHER,RECOIL STARTER
BOLT,HEX HOLE,5X25WS
COLLAR,TANK FIXING
PIPE,FUEL,3X5X230
CLIP 6.3
FILTER,FUEL
TANK,FUEL (ORANGE)
TANK,FUEL (WHITE)
COLLAR C
CAP,FUEL BLACK,NON VENT
AIR VENT VALVE ASSY
PIPE,AIR VENT
VENT,AIR ASSY
BOLT, HEX 5X20
BOLT, HEX 5X20
STAND,ENGINE
PIPE,FUEL,3X5X100
CLIP,5.5
GROMMET,FUEL PIPE
BOLT,HEX,5X30S
WASHER,5
GASKET,TANK CAP
www.tanakapowerequipment.com
Page 15
QTY
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
2
2
1
1
1
1
1
1
3
1
1
1
1
3
2
1
1
1
1
1
1
1
COMMENTS
S/N U207705 and after
Before S/N U207704
S/N U207705 and after
S/N U207705 and after
S/N U207705 and after
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PARTS INFORMATION
PF- 4000
RECOIL STARTER • FIGURE 5
ITEM
5-0
5-1
5-2
5-3
5-9
5-12
5-14
5-17
PART NUMBER
7620422090
7720422080
7690422020
7790422020
7830422020
8350422020
7850422020
8390422020
DESCRIPTION
STARTER,RECOIL ASS'Y
BODY,RECOIL STARTER
REEL,STARTER ROPE
SPRING,RECOIL
ROPE,STARTER
CAP,HANDLE
HANDLE,STARTER
SCREW,SET
www.tanakapowerequipment.com
QTY
1
1
1
1
1
1
1
1
Page 16
COMMENTS
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PARTS INFORMATION
PF- 4000
CARBURETOR • FIGURE 6
ITEM
6-0
6-1
6-4
6-5
6-6
6-7
6-9
6-10
6-11
6-12
6-13
6-14
6-17
6-18
6-19
6-20
6-21
6-22
6-24
6-25
6-26
PART NUMBER
4550440090
51425100200
54425164200
53925120200
5492516520
48925100200
61425137200
55025100200
5992001W44
99101060013
~~~
~~~
57825007200
5752515380
~~~
~~~
4762515120
5482515120
4310634C200
4422515180
44725108200
DESCRIPTION
SET,CARBURETOR
SCREW,THROTTLE SET
STAY,ADJUST,CABLE
SWIVEL
WASHER,THRUST
RING,STOP
ADJUSTER,CABLE
O-RING
JET,MAIN,LONG,#44
NUT,6
GASKET,PUMP
DIAPHRAGM,PUMP
SCREEN,INLET
BODY,PUMP
GASKET,DIAPHRAGM
DIAPHRAGM,METERING
COVER,DIAPHRAGM
SCREW,SET
GASKET,CLEANER
PUMP,PRIMING
BULB,PRIMING
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QTY
COMMENTS
1 Includes carburetor gasket
2
1
1
1 ~ Contained in Carb Repair Kit
1
P/N 650-25124-900
1
(Not available individually)
1
1
1
1
1
1
1
1
1
1
4
1
1
1
Page 17
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