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F i t t t t . I w a n t t o t h a n t z A o u d o n q o u r Lt u p p o t t t o v e , L t h e p a d t q e a " n t . T o a 0 u
w h o h a v e e l n o , s e nu 6 6 o n A o u t Ln a e i n g n e e d t a v u L A t p e c i a l
thanlz Uou.
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b l c t w i n g . W z t " t -I ' m n o t g o i n g t o t n q a n d i m p t t e , s aA o u bq exd"ggenatingon h o w
b L g m L Jo p z t t a . t . i o ni t , o L h o w m a . n qF a . e t o n - O
q n i v e r t t w e ha"ve.
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b u i t - d i - n ga t - L t . q p e t o ( R a e i n g E n g i n e ' s d o n t | t e F a e t o n i e d a n d ? n i v a t e e n t
a l - i h e . T l t e r e L J e a , LoAd E x p e n i e n c e a , n d K n o w L e d g eg a L n e d g o i n t o e v e n q E . C ,
E n g i n e t h a t w z b u i l d . T h e R e c o n d B o o l z aw i L L t h o w t h o , t ) u n E n g i n e a a n d
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F n o mt l t e S a I - t F L o , t t o { B o n e v l l L e t o N a t . i o n a l -l l Z M L L e a n d S h o t t t T n a " c l z
E . C . P o w e n e dM o t o t t e q e L e d| t a v e 6 e . e nm o t L et | t a . n t l ' t e i n t l t a n e o d C h e . e l z a nFdL a g t .
l l s M L L I a n d 1l l M L L I 0 t t a g R o . e i n gL t o . n o t h e n ( L e t - d t h a . t w e h a v e h a d o u n
S h a n e .o 6 W i n t i n a L a o . T h i t A e a t La 6 L a r t q e a " r w
L e wil-L o(6en a Complete
L L n e o { R a c L n g P t o d u c t t $ o n A L I - C L o t a e t o ( K a n t L n g, 4 l C q c L e a n d 2 l C q c L e ,
F o n t h e E n d u n o 0 t i v e t u ) e K n o w A o u n N e e d , s ,a n d h o w t o B u i l d U o u a E n g i n z
t hat I L I - L t o "b e A o u d n o m tl 'te S ta " n t t.o tl+ e Finiah. Thia Knowledge com z6 ( non
8 e a t . i - n gn q E o d q a t t o u n { S o u t h e t t n C a L L { . 0 e t e t L t R a . c e t a n d E n d . u n ol l z e t t .
A m o n gt L t z t e m a . n uC n o a ' sC o u n t t t q R a c e t t h e R e c o n d s w i I - L a l t o w t h a . t a " n E . C ,
P c t w e n e d1 2 5 N o n t | t e M L n t 4 0 0 i n L a t V e g o . a .E . C , E n g i n e t t e t t h e p d e e ( o n
) t | t z n - d t o t a L I - o w . T h i ' s K n o w L e d g eo d D e p e n d a b i l i t t 1 T n a " n t { e n t 0 i n e c t l q t o
Kanting.
T l t e C o m p a n qP o L i e q o d E . C . 0 i a t .
h a , sa L w a q t b e e n o n e o { w h e n e o u r t C L i e n t t
m e a . nm o t L et o u A t h a n j u t t a n o t h e n d a l e . B e e a u , t e0 6 t h e a e d e e l i n g a I h a v e
jutt
cone ta t|te decitLon that Ltaving tomeone eLte wttLte thit ea"to.Log
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eventhing thetl want t.o 6aq. TlnLt atqle o$ wziting tel-La Uou next to nothing
about tlnz pnoduct, ott wltat tl'te ModidieatLon wiI-l- do 6on Aou, I (zel ntl
C L i e n t t O e t e t t v z t t n i g h t H o n e t t T n d o t m a t i o n , S o i n m q o w n C o u n t n q B o t Tw a q
I'm going to tnA and ca,L,LA
U o u ( z o m t l t e d n o n t p a - g et o t h e L a a t p a g e w i t h o u t
boning tlou to Death.
A ) e n ea . I - w a q tA d d i n g N e w P n o d u e t t t o o u n L L n e , a n d l u , L , L e 6 e a " n edho n M o n e
H c s n a e p c w enne v e t LS l o p a . S o i 6 U o u d o n ' t t e e w h a t q o u w a n t . L i a t e d o n U o u
j u , s t n e z d A o m ea d v i t e , d t o p u 6 a L i n e o t L g i v e u A a - e a . L L . W e w i l t - d o a L L
u)ecan don Aou.
W i t l n m q T z c t r t . P i z c e t 6 o t t t . L t e M a , g a " z i n e ,As o m e o n e a . L w a " q te d i t t m A A t o n i e a , a n d
e L z a n r u p m q b o , d a p e L l i n g a n d e n g L i t h . N o t , s o l t e n e , A o u w i L L d i n d A o m em i t t p e L L z d w o n d ' s h e n e a n d t h e n z ; b u t d a n c q a d v e n t i d i n g a " n d S u p z n Tniclz Catd l ogr
N E Y E RI I J ( ) N
A RACE.
T l , L a n t <adg a i n ,
a " n d w e l e o m e -a b n o a d t h e E . C . R A C I N GT E A M .
PnlH$t[ilErEl[
There is a certain quality and attit u d e ' t h a t s e p a r a t e so n e s p e e d m e r chant from another. lt takes a lot of
k r r o w l e d g e ,p r a c t i c e , c a r e a n d p r i d e
l o e s c a l a l et h e s e p e o p l ef r o m t h e r e s t
in a crowd. E. C. Birt and Precision
C y c l e i s j u s t s u c h a n o p e r a t i o n .R e cently Birt's shop was chosento do
the porting work on Cycle Guide's
P r o j e c tM a i c o . T h e r e s u l t sw e r e p e r f e c t .l t ' s n o a c c i d e n t h a t t h i sj o b a n d
d o z e n so f o t h e r s h a v e e a r n e d P r e c i sion Cyclea good reputation.
Birt had worked on German machinesfor more than five years and
workedat Mccormack on the Americ a n E a g l e s .H e i s a c t i v e i n r a c i n g
h i m s e l fh a v i n g h e l d t h e # 5 p o s i t i o n
i n t h e A C A - 1 2 5C l a s s P
n ycle
. recisioC
p r e p a r e dM i c ro - M e t i s s easr e c u r r e n t l y
r u n n i n gw i t h 2 5 O ' s a n d 3 5 0 ' s . T h e
m o s t o u t s t a n d i n gv i c t o r y c a m e t w o
y e a r s a g o a t t h e W e s t l a k eV i l l a g e
V i e w f i n d e r sR a c e .G a r y B a i l e yr o d e a
S p e c i a l1 0 0 c c H o d a k at o a f i r s to v e r a l l
w r n a n d t h e S w e e p s t a k e sT r o p h y .
I n r s w a s a .r a c e a g a i n s tm a c h i n e su p
t o b t t m e sl a r g e ra n d t h e H o d a k aw o n
r I r u n n t n ga w a y .
P a r t o f t h e i r c u r r e n ts u c c e s sc a n b e
a t t r i b u t e dt o L u t h e r" P o p p a " D i l lw h o
h a n d l e sa l l o f t h e p r o t o t y p em a c h i n e
w o r k . T o m B r o o k e sd o e s m o s t o f t h e
p r e c i s i o nw o r k a n d w a s o n c e a m a c h i n i s tf o r e m a n a t N o r t h r u oA v i a t i o n
hn dd e v e l o o m e n t
a s w e l la sa r e s e a r c a
e n g in e e r .
N e a r l ya n y o p e r a t i o nc a n b e h a n d l e d b y t h r st e a m a n d i t c a n e v e n b e
handledby mail. While we were
t h e r e , a S a c h s s n o w m o b i l ee n g i n e
a r r i v e di n a c r a t e{ r o m l d a h o . l f v o u
a r e l o o k i n gf o r h o p - u p w o r k t h e n y o u
s h o u l di n c l u d et h e f o l l o w i n gi n f o r m a tion:
1. Type of use-MX, TT, etc.
2 . R i d e rc l a s s - A M , E X , N O V .
3 . R i d e rw e i g h t
4. Terrain
5. Elevation
6. How much you're wrllingto
speno.
B i r t s a y s ," W e ' l l g e t i t o u t o f t h a t
e n g r n e h o w e v e r p o s s i b l e , "a n d h e
m e a n si t . l f y o u w a n t p r i c ee s t i m a t e s
t h e n d r o p a l i n e t o . P r e c i s i o nC y c l e ,
D e p t . C M , 1 4 1 2 7 H a w t h o r n eB l v d . ,
L a w n d a l e ,C a l i f . 9 O 2 6 0 o r p h o n e
( 2 1 3 16 7 6 - 6 1 2 3 .
April 1971
Cycle Mechanics
SLIPS
T
AtflOST
TVTR}/II{II*|G
II{AI
}/OU
\'lAl'|IT
OKt'|O\'l
ABOUT
TILLOTSOI'|
TARBUR
(BUIltlTRT
ATRAID
IOA'OPArIl
This month we are happy to wetcome
a new membet to the writing stalt here at
National Katt News. This is the lirst of several parts on the complex bui lascinating
world of carburetors that E.C. Eirt has written.
E.C. has been a major lactor in karting over the past
two decades thtough his work with Tillotson Ltd both as
an advisor and head ot their R & D Center. To mosl at
least in the motorcycle or kailing lrade, E.C. is well known,
but to any newcomers we will give you a briet took at
what this man has accomplished ovet the last three decades. We could probably write a book on all his personal
accomplishments, but we'll let him do that. ln lhe early
si,rlies, he was involved in motorcycle racing and helped
develop the technology still being used in todays racing
bikes. His innovations as an engine tumer labeted him the
"Guru'of the l00cc and l25cc motoctoss engines. He
helped design and prcmote the Mini Grand prix bike craze
ot the sixties and holds morc than a couple records in
both drag bike and moloctoss racing.
ln his spare time he managed to ollet his
se.yices to several ol the leading motorcycle
magazines and newspapers as their Technical Editot. His articles included factory
testing ol racing components, evaluation
testing and How-to anicles lor motorcycle
racerc and karters alike. ln the lale seven-
ties, E.C. became involved in kail rccing
and took on the task ol being Technicat
Editor lor several Karting magazinesas welt
as holding national seminarson racing carburetorsand engines.His involvementwith
Rarting started simply enough as a hobby
and pastime to get away lrcm the pressures of motorcycling,but his talentshave
quickly been recognized and utilized in this
sport as well. E.C. maintains a lully
equipped racing shop for lactory and privateer contenders and continues to build winntng components in the mototsports filed.
In the past lew years, E.C. has helped develop the popular ECH-3488, the ECHL355A and the ECH9-191GTillotsoncarburetorc for kart racing.
We are very proud to have E.C. join
lorces with us. His column wil! be entiiled
"Slip Stream'and will cover a varietyol topics on carburetorc and karting in generat. E.C.
will also welcomeyour commentsand questions
which you can address to "SIip Stream.c/o National KarI News 51535 EittersweetBd, Granger, lN.
46530
National
KartNews/ January1993
TillotsonLtd., Clash IndustrialEstate,Tralee,Co. Kerry,lreland.Tel.353-66-21911.Telex 852/73010.Telefax353-66-24503.
Decenfter
7992.
TO ALL TILLOTSON LTD MASTER MANUAL HOLDERS
Enclosed
please
fnd tlrc 1993MasterPriceList, NezuApplicationnnddescriptionCntalog,
Teclmical
up-dateBulletinsNo. 1.57andNo. L58andsupplementary
PartsListsfor newHS models.
TillotsonLtd ntaintainedafx pricethrough1991./1992.
Theincrease
for 1993lns beenlrcltlunder4% with
reductions
on certainparts.
With regardto Seraice
itentaaailability
andquality,if youlnueanyproblents
or questions
please
contactus.
We tlnnk youfor your supportin 7992andwe lookfoutnrdto a mutuallyreutnrding
yeuralrcad.
MICHAEL QUILL
SALESMANAGER
ATTENTION KARTING FANS;
For all your TillotsonKartingcarburetors
contact:
E.C.BIRT,
1.309OLD CHARLOTTEPARK
D/CKsONTN.3705s,
PHONE;615-446-6807
FAX:615-445-9418
olillolson,
@.9*4\.
'kEEpsYA'#Iftl:tlftrlfr
S U P ES
RT O C KL,I I I I T E DI { O D I F I E DI I,O D I F I E D( ), P E i l SJ, R . D R A G S T ELRI 4, } I I D G E T
L E e r u r N l ' / . K . A . , I . K . F . A N D0 . | v | . A .
B L U E P R I I {H
TL
, - 1 4 8 7/ 8 V e u r u rR wr r H 1 . 0 0 0 r H c n T n n o r r u r S n R r r
You say that you have broken enoughrods, Built enough Bay tfindow Blocks
Your buddy gave you a man'ifold and
or just have the need to Go Faster.
'
i
all you need s a Tillotson Carburetor; or maybe you just want to retire
the 0ld Tillotson
Carburetor that you have and advance up to todays'
Your new
Then this is the carb for you.
State of the Art Tillotson.
T i l l o t s o n w ' iI I b e B L U E P R I T I T EBD
Y US to f it the Type of Racing that you
do.
Dri II pattern wiII be put 'in to f t your type of motor and tracks.
A n E . C . R E DT I P S U P E RS E A L t I E E D L Ew i l l b e p u t i n a n d t h e P 0 P - 0 F F P R E S S U R E
wi l l be set.
You wi I I al so recei ve an E.C. TRICKSHIII KIT and ALL TUllIllG
I t { S T R U C T I 0 t I S .F o r t h e D O L L A RI t { Y E S T E D
t h i s w i I I b e t h e m o s t B A l { Gf o r t h e
B U C Kt h a t y o u w i I I e v e r g e t .
h J h e nw e ' r e b u i 1 d ' i n g y o u r c a r b a n d y o u w a n t
a n E . C . V E L O C I T YS T A C K f i t t e d
All
so note it on your order.
to jt,
Carburetors come with tuning instructions and service guidel ines.
P A R T*
DESCRIPTION
H L- 3 4 8 C
T ' il l o t s o n C a r b u r e t o r
with B/P I nformati on
EC-SSA348 Super Stock, Sprint
EC-SSD348 Super Stock, Dirt
E C - L l . l A 3 4 8L i m i t e d M o d . , S p r i n t
EC-Ll,lD348 Ljmited
Mod., Dirt
EC-1.10434M
8 od. Briggs, Sprint
E C - 1 . t 0 D 3 4 8M o d . B r i g g s , D ' i r t
EC-QU348 l/4 Midget, Asphalt
or Dirt
E C -J R 3 4 8
Jr.
4 B -I 1 { S
Veloc'ity Stack
installed on carb.
Dragster
N O T E :F o r t h e K a r t e r t h a t i s r a c i n g o n a b u d g e t o r j u s t e n j o y s d o i n g h ' i s
own Blueprint work.
All E.C. HL-348C Tillotson
Carburetors come w'ith
B l u e p r i n t I n s t r u c t ' i o n s a n d a t ^ l e l c h P ' l u g . P A R T' E C - H L 3 4 8 C
M y 2 5 p l u sy r s . E x p e r i e n c ies c h e a p e trh a ny o u r M i s t a k e s .
1309 of d charlotte Pk.,Dickson,Tn.37055.P[f.615-116-6t07
4
olillofson. q%ge4\o
Stat€-of-the-Art
)
)
F t
0l
t, H,S:
B 0 I S T 0 C KR a c i n g ' i s t h e m o s t c o m p e t i t i v e c l a s s
W h e n' i t
of Racing that you could ever ask for.
comesto this class of racing thene is no way
t ^ l h yt h e
that you can cut anyone any slack.
picture of an 0pen Motor? A Box Stock Carb
has very l'i ttle class and everyone has seen
o n e . W h a t ' s t h e b o t t o m I i n e ? S i m p le . T o
win in the stock class the carb needs to be
just as trick and have the sameworkmanshi
as this 0pen Motor but done in a way that
get thru the Tech Barn.
it will still
B O XS T O CB
KR I G 6 S :
This is a NewCarb. Drilled fo
S T A G Et l
A l k y a n d h a s 3 F U E L F L 0 l f E Dl l A I l { . r E f S m a d e f o r
it.
Throttle arm is also set on the FL0H
B E I { C Ht o g e t t h e m a x a i r f I o w o u t o f t h i s
level of carb. This is a good unit for Entry
Level Racing.
B O XS T O CB
KR I 6 6 5 :
S T A G Et 3 ' T I I I L I G H T Z 0 t { E ' T h i s c a r b h a s a l I t h e
' T R I X ' d o n e t o ' i t a n d Y E S , I T I fI L L S T I L L G 0
T H R UT H E T E C HB A R t l . T h i s t y p e o f c a r b i s b uj I t
T h r o t t l e b o r e i s m a c h 'ni e d f o r m a x i m u mA ' ir F l o w .
o f f t h e F L 0 l f B E t { C Ha l s o .
In short, thi s
T h i s C a r b a l s o h a s 3 F U E L F L O tEf D I | A I N J E T S l , l A D EF O R I T .
' i s t h e c a r b t h a t i t t a k e s t o t fl t { A l l A T I 0 t { A Lo r g o p l a y H A R DB A L L .
E . C . ' K I L L E RF I L T E RK I T ' :
I F Y O U L I K E Y O U R M O T O RA N D l , l A N TI T T O L I V E F O R A h J H I L E ,T H E N Y O U N E E D O N E
FILTER KITS.
OF MY RAMFLOhJED
KP P E A R I lC{ G
ARB:
E . C . ' O V E R K I L LS' T ( ) CA
No way
I n s o m e a r e a s , t h e r e a r e s t . i ' lI s o m e o f t h e s e c l a s s e s r u n n l n g .
around 'it.
I can and do make the best Carb you can get for this class.
The only problem is, I have on'ly one way to do 'it and it does cost to
b u ' il d a C a r b f o r t h i s t y p e o f c l a s s b e c a u s e ' i t c o n r e s c o m p l e t e w ' it h C a r b ,
T a n k a n d t " 1 ani J e t s .
"KEEPS
YAo#Ifllllllfr
M y 2 5 p l u sy r s .E x p e r i e n c ies c h e a p e trh a ny o u r M i s t a k e s .
13OgOld Charlotte Pk.,Dickson,Tn.37055.Pl{.615-146'6t07
ofillolson, @.9.4.
Stat€-of-the-Art
S U P ES
RT O C KL,I I I I T E I } SJ, R . D R A G S T E R :
S T A G Ef 1
Thi s Ti I I otson Carburetor i s the next step up from an E.C.
B L U E P R I N T EHDL - 3 4 8 . T h i s S t a t e o f t h e A r t
Carburetor.i s Designedoff
the Flow Bench. Tee Slotted for
more Fuel Flow, E.C. Red Tip Super
S e a l N e e d Ie t o c o n t r o l p o p - o f f
pressure and Velocity Stack fi tted
to the carb. The Throttl e Shaft i s
m o di f i e d f o r i n c r e a s e d A i r F l o w .
Th'is i s the perf ect Entry Level Kit.
C o m e sc o m p l e t e w i t h E . C . R a n F l o w
l , l a n fi o l d , E . C . F u e l P u m p , E . C .
Linkage Kit and Trick E.C. Filter.
S T A G E# 2
This is the
I ' l e e k e n dl l a r r i o r i n C o m pel t e
Kit Form and goes beyond a
Stage fl Kit.
Thi s 'KILLERU
S E T U P C A R Bh a s b e c o m e t h e
Standard that ALL 0THER
E N G I N EB U I L D E R ST R Y T O C O P Y .
N e e d a L I T T L E l , l 0 R EE D G Et h e n
this K'it will get it for you
S T A G E# 2 + 2
The need to G0
F A S T E Ra n d j u s t t o u c h o n t h e
0 U T E RL I I " l I T S o f t h e T I I I L I G H T
Z 0 l { E b r o u g h t o u t t h e D E S I G I {0 F
T H I S G R A N DN A T I O N A L} I I I { N I I { GK I T .
'l
R0Hll M00N of M00N P0l{ER i s one of the
e a d i n g E N G I t I E B U I L D E R So n t h e
N A T I 0 I { A LC I R C U I T a n d t h i s i s t h e r e c o m m e n d e dE . C . C A R B U R E T I 0KTI{T f o r H I S
C L I E N T S . M a n y G R A N DN A T I 0 I { A LC H E C K E R EFDL A G S h a v e b e e n t { 0 t { t d I T H T H I S
U i { I T . T h j s u n ' i t i s c o m p l e t e l y B U I L T ' 0 F F T H E F L O t l B E l { C Ha n d i s a B 0 L T0 1 1
I{II{NER.
T I { I L I G H TZ O N ET I L L O T S O N :
S T A G E# 3
T hi s i s t h e U 0 V E R K I L LC A R B K I T n T H A TT H E H A R DB A L L P L A Y E R S
U S E . T h i s K i t h a s b e c o m et h e S t a n d a r d f o r t h e R A C E R SE D G E , l . | E E KA F T E R
l,lEEK. Every detai I of perfect'ion goes into the creat'ion of one of these
Carburetors.
The choice of the best I i ke Scottie Cagle, Rohn ltloon,Jody
Jolly, Ron Barfield, Jim Bryant, C.H. Kelly, Ralph l{oodard and manyothen
Nati onal Uinners.
Tt'lILIGHT Z0l{E, HEGAP0t{ER:
I s thene Life
after
a RIDE THRU THE T}lILIGHT Z0l{E. You bet!
Just ask
R o h n M o o n , S c o t t ' i e C a g ' l e , E d d i e R a l p h , L a r r y D a vj s a n d
.
This
Tillotson
P a c k a g e i s l ' i k e l o o k ' i n g a t a R 0 L E X l ' l A T C Ha n d j u s t t o o t r i c k t o
talk about.
You're right,
is the one that gets wrapped up in a Rag
thjs
in the fech Barn.
"KEEPS
YA:*IllllItlI
oTillolson,@D.g.4\.
Stat€-of-the-Art
KARTII{G
AilDL/4 }IIDGET
100cc ZICYCLE
A i l DD 0 U B L E
A's:
B L U E P R I l { tTh r u ' 0 Y E R K I L L T } T I L I G H TZ 0 t { E ' 3 + 3 l . l E G AP 0 l { E R :
'l
The Ti I I otson that you are
o o k ' in g a t h e r e , w a s o n e o f m y b e t t e r i d e a s
and one of the most versatile
All
units in my arsenal for Racing.
the
way. from
RADI0 C0t{TR0LLED AIRPLATIES to
F O U R t fH E E L R A C E R S . T h ' is
carburetor body has the same I1{FIIIITE RADIUS as that
of the HL-348 which
has a 7/8 Venturi w'ith a 1.000 Throttle
This carburetor has a Venturi of .945
Shutter and it's not just a b'ored
Karting, th'i s carb is an HL-36
D R I Y E2 / C Y C L E S . N e x t o u t o f
w e b u i l d t h e H L - 3 5 5 w h ' ic h i s
u s e d f o r A L K Y C A R B S ,? I C Y C L E ,
l , l 0 0 I F I E DB R I G G Sa n d 0 P E l { S o , , ' i
I n l l 4 I I I D G E T St h ' i s i s t h e
body that we BUILD the
. 9 4 5 A L K Y C A R Bo u t o f
f o r t h e D 0 U B L EA ' s a n d
s o m el l 2 I I I D G E T S .
Shutter.
and a 1.060 Throttle
out HL-348. In
for 6A5 DIRECT
this samebody
K A R T I T { GW
: ant to bui I d ffi
a g o o d r u n n i n g I I { E X P E i lf-f i
S I Y E O P E I {C L A S SI { O T O R :
T H A Tw i l l r u n w i t h a
$1,500.00 Plus Control.
Just put one of my ALKY
SETUP HL-355 KITS on
y o u r L E G A Ll 0 0 c c Y A I . | A H A .
You won't believe the l,lEGA
P 0 } , E RG A I I { Sw i t h t h i s k i t .
introduct'i on of the E.C. .945 DOUBLE
A
I t h i n k E Y E R Y1 { E } T
, R A C K R E C 0 R DH A S B E E t I
'FL0}l BEt{CH' DESIGI{EDand BUILT TILLOTSOI{
SET l{ITH an E.C..945
C A R B U R E T OKRI T
A g ai n I p o ' in t o u t t h a t a T I L L 0 T S 0 t { C A R B U R E T 0tR
h a t ' is
b u i l t f o r K a r t i n g c a n l e a d t o ' S H E A R D I S A S T E R ' I F Y O UT R Y T 0 U S E I T O t l A
l / 4 l ' I I D G E T . T h e s e c a r b u r e t o r s h a v e t o b e b ui I t o f f t h e F L 0 l f B E l { C Ha n d
the FUEL DISCHARGE
P O R T Sh a v e t o b e C A L I B R A T E D t o
f i t your type of
RAC
I I{G.
As wi th al I
E . C . C A R B U R E T 0 Rt hSe K I T S C 0 l . l EI fI T H ; F L O l t B E I I C H
D E S I G l { E DC & C I . I A C H I N EBDI L L E T l . l A N I F 0 L D S . V E L 0 C I T Y S T A C K Sa r e F I T T E D a n d
b e c o m ea P E R M A i l E t {PTA R T o f t h e C A R B U R E T 0 RL. I t { K A G EK I T S a r e a I s o p a r t o f
t h e P A C K A G Ea n d a l I l 4 0 U N T I l l cH A R D T { A RCE0 M E S} fI T H I T .
W e a l s o s u p p ly
compe
l te service information and tuning tips.
The bottom I'i ne i s, when
y o u g e t a n E . C . C A R B U R E T I 0K
l {I T i t i s a C 0 M P L E T ET U R I { K E U
Yl{IT, DESIGI{ED
and BUILT to l{IN RACES. Depending on your
Racing Budget, we have
E . C . K I T S r a n g i n g f r o m B L U E P R I N TE N T R YL E V E L t o 3 + 3 t I E G A P O l f E R . J u s t
r C m e m b e rt h a t . I , I Y ? 5 P L U SY E A R SO F E X P E R I E N C IE. I I L L B E C H E A P E R
T H A I {Y O U R
IIISTAKES.' I'm here to help you and all you have to do it ask so I can
design the E.C. KIT that fills
your Racing Needs.
ll4 iIIDGETS: Si nce the
ALKY KITS a few years d9o,
7
orillofson,q%s.4.
Stat€-of-the-Art
S JR. DRAGSTER:
i I 0 D I F I E IBI R I G G S , ( ) P ErI rI o
S T A G E# l t h r u 3 + 3 l { E G A P 0 } f E R- - T h e s e t y p e s o f I . l 0 T 0 R Sa r e D E F I T I I T E L tYh e
H E A R TP O U N D E R S t. { 0 T H I t { Gi n t h e H 0 R L D S O U i { D S
a s G 0 0 0 a s a n 0 P E t {l l O T O R
at
9,000 plus R.P.M.'s.
E v e n a G 0 0 D! I 0 D I F I E DB R I G G St h a t i s b u ' il t r i g h t i s
m o r e t h a n a H A t { DF U L L f o r a n 0 P E 1 { . I n t h e p a s t t h e o n l y C a r b u r e t o r t h a t
w a s a v a i I a b l e f o r t h e s e M o t o r s w a s t h e S I , I A L L ETRI L L 0 T S 0 t { H L C A R B S . T h e s e
c a r b s h a v e a 7/ 8 V e n t u r i a n d 1 . 0 0 0 T h r o t t l e V a l v e a n d a r e j u s t t o o s m a l l
for
these heavy motors.
Back a few years
d9o, I designed and had TILL0TS0I{
build a Carburetor for these
engines. This Carb (labeled
HL-355) has a .945 Yenturi
with a 1.060 Throttle Shutter.
{.
This has turned out
as bei ng the choice
&
of choi ce Carburetor
for your Eng'ines. If
you're just getting
started in one of
t h e s e H E A Y YH I T T E R
Classes, a Stage tl
or Stage #2 FLOlt
B E N C HD E S I G t I E D
and
BUILT KIT wi I I get
the job of lfltlt{I1{G
D0NE. If your
Saturday night
T H U t { D E hRa p p e n s t o
t a k e ' in a N A T I 0 N A L
or the BIc $$$$ RACES
then you may have to
move up to a HIGHER
L E V E La n d S T A G Eo f
an E . C . H L - 3 5 5 l { 0 R L D
B E A T E R . W h e n i t c o m e s t o a n 0 p e n E n g in e s o m e o f y o u h a v e y o u r o t r n
Man'ifold design, fuel pumps and etc.
I d o n ' t h a v e a p r o b ' l e mw i t h t h ' i s .
I can and wi'll bu'ild for you, just the Carburetor with a Ve'locity Stack
on it.
T h i s c a n b e d o n e f r o m j u s t B A S I C E I { T R YL E Y E L t o t h e } I E G A P O l l E R
3+3 Ul{IT.
I n t h e c o m p l e t e k i t f o r m t h e E . C . M a n 'fio l d ' i s D o u b l e T r i c k .
Whenit was designed, the hole where it bolts up to the block (rhich is
.940) i s of f set.
B o t t o m I ' i n e : b o l t t h e m a n 'fi o i o t o t h e b l o c k a n d s c r i b e
a I j n e u s i n g t h e m a n 'fio l d a s t h e p a t t e r n .
Now remove the manifold and
port the block to fit.
T h ' is c u t s d o w n t h e n e e d f o r a F L O l t B E t { C H . A s t h e
o l d s a y g o e s ' l , l Y ? 5 P L U S Y E A R S0 F E X P E R I E T { CI E
S C H E A p E RT H A I { y 0 U R
M I S T A K E S ' . D u e t o t h e F U E L F L 0 t { D E S I G I I 0 F T H E S E C A R B U R E T 0 RaSl I u n i t s
f r o m E l { T R Y L E V E L t o l . l E G AP o l { E R , H A V E E . C . R A M F L 0 t { t { E E D L EA i l D S E A T
A S S E I " I B L I EI N
S THEt'|. If you're raci ng on a track where there j s no FUEL
y
R U L E S a n d o u a r e u s i n g a H E A V YL 0 A D o f F U I { N YF U E L , I e t m e k n o w a n d I
w i l l d e s i g n y o u r c a r b t o L 0 V E B 0 T T L E DH 0 R S E p 0 l r E R .
#
"KEEP'YA:{)lllil#rg
oTillolson,@.9.4\.
Stat€-of-the-Art
I O, D I F I E rDr n
G A So R A L K Y ,S T O CA
KP P E A R I I I|G
B IIODIFIEDS:
B L U E PI IRI T T H R U5 + 5 ' T Y I L I 6 H TZ 0 l l E ' I I E C AP 0 U E R T
ArD ]^ltl I I I D G E T
KARTIIIG
I Iike a Class that is a non-tech type or very
little
tech.
This type of Racing Class
cuts out a I ot of the NIT PICKING. In
short, "come and run what you brung."
The key to this type of
Carburetor Kit on'ly comes
after years of EIPERIEIlCE
and UIIDERSTAT{DT
I tH
I GE
] I E E D SF O RA S P E C I F I C
T Y P E0 F l l 0 T 0 R . L e t ' s
look at Karting first.
D e p e n d ' i n go n w h e n e
you're at and the
rules that you have to
race under controls the
type of Fuel that you have to
use. Thi s i s no probl em for me.
J u s t l e t r n e k n o w i f y o u u s e G A So r
A L K Ya n d I ' l I s e t y o u r C a r b t o r u n
on that type of fuel for you.
l l 4 n I D G E T S :A s i n K a r t i n g , H O R S E P0IER is like HAI{BURGE
} IR
EAT. YOU
C A t l B U Y A L L Y O Ut { A t l T . T h e Q U A L I T Y
and Al,lOUt{T
is up to you.
In
the I ast f ew years, EllGItlE BUILDER
a n d F R A l , l ED E S I G I l
TECHI{OLOGY
h a s g o n e b e y o n d t h e c a p a b ' Ii i t ' i e s o f
C A R B U R E T O R0SF T H E P A S T . D u e
t o t h e H I G H G F 0 R C E So f t h e s e C a r s a n d E n g ' ni e s t u r n i n g 9 , 0 0 0 R . P . M . ' s
and has al I but OBS0LETED
a n y F L O A TB O I L S T Y L EC A R B U R E T O R .H 0 R S E P 0 I E R
I S I t l D I R E C TR E L A T I 0 I { T 0 A I R F L O t f a n d t { 0 } I 0 T O R C Y C LCEA R B U R E T O
CR
All C0}lE
C L 0 S E T 0 T H E A I R F L O t f 0 F A T I L L O T S O I {C A R B U R E T O R
THE
S ,I z E f o r S I Z E .
G F O R C E So f t h e T R A C Kc a u s e s F U E LT 0 C L I I I B I t l T H E F L 0 A T B 0 I L , w h i c h m a k e s
) AnBUnET0RS
f o r F L A T S P 0 T Si n t h e r U i l I i l G .
T h a t i s w h y T I L L o T S o i l ( P U H P E RC
a r e S U P E R I 0 Rt o F L 0 A T 8 O t f L C A R B U R E T 0 R Sl.l 4 I , I I D G E T St a k e a T I L L 0 T S 0 t I
that i s DESIGIIED
J U S T F O R l l 4 I . I I D G E T S . I n s h o r t , n o K A R T I l { GC A R B U R E T O R
w i I I w o r k p r o p e r l y a n d S H E A RD I S A S T E R
IIILL FOLLOI by try i ng a Kart i ng
C a r b u r e t o r o n a l l 4 I I I D G E T . A L L E . C . T I L L 0 T S 0 I I C A R B U R E T 0 Rf rSo m E I { T R Y
L E Y E L t h r u 3 + 3 ' T I f I L I G H T Z 0 l l E ' l ' I E G AP O lEf R c o m e i n c o m p le t e K I T F O R t l .
T h e s e E . C . K i t s h a v e j u s t a b o u t s e t E V E R Yl { E t { T R A C KR E C 0 R Dt h e r e i s a n d
e n o u g h G R A I { Dt l A T I 0 t { A L t l l t { S t h a t I h a v e I o s t t r a c k o f t h e m .
A l l k ' it s
c o m e w i t h E . C . l . l A l { I F 0 L D SL, I I l K A G EK I T S , S E R Y I C EI I I S T R U C T I 0 l { S
and TU1{I1{G
I]{F0Rl,lATI0N. l{0TE: Modifieds use a different manifold than a B Modified.
I f y o u w a n t t o u s e t h e C a r b u r e t o r o n a B M o d 'fij e d a l s o a d v i s e m e a n d
I c a n s e t t h e C a r b u r e t o r u p w ' it h M a n i f o l d s f o r e a c h m o t o r . I k n o w t h a t
for most of you, a change over from a Float Bowl type of Carburetor to
a Pumper is a scary thought.
But in time, to be corrpetit'ive, you will
have to make the change.
Don't 'I{0RRY'.
When I bui'ld yout^Carburetor
L A P T I l , l E SI I I L L B E F A S T E Ra n d y o u w i I I a l w a y s h a v e m e t o H E L PA l l D A D Y I S E
Y0u.
olillotson, @.9.4*
Stat€-of-the-Art
E.C. BLUEPRIl{T COI{TROLS:
The ECHR-l9l is the llElf KID on the BL0CK,I.K.F. and lf.K.A. LEGAL. t,lith
T O D A Y S ' l l E l {S T A T E0 F T H E A R f i l O T O R Sa n d S T I I I G E RP I P E S , I h a v e d e s i g n e d
this carb to fill
t h e K A R T E R SITI E E D So f h a v i n g a C A R B U R E T Ot hRa t i s v e r y
n
F
R
I
E
T
{
D
L
Y
.
I
s h o r t , y o u d o n ' t h a v e t o L E A R I It o D R I Y Ew i t h o n e H A I I D
USER
o n t h e S T E E R I I I GI f H E E L a n d t h e o t h e r o n t h e
C A R B U R E T 0t oR K E E P
y o u r m o t o r f r o m S E I Z I t I G a n d T U R I I I I I GI I { T 0 a
O T { EP I E C EU I I I T .
short, as
T h e E C H R - l 9 l i s a 3 4 m m S I Z E C A R B U R E T 0 Ri ,n
b i g a s t h e T E C HR U L E SA L L O l ff o r t h e
r*
C 0 t l T R 0 LC L A S S E S . F o r t h e m o s t p a r t , t
t h i s i s t h e r e c o m m e n d e dC a r b u r e t o r n o w
of the Eng'ine Importers and if you' re
l l E L t o t h e C O I { T R 0C
L L A S Sa n d E I { T R Y
L E V E LB L U E P R I i l fj o b i s a l l t h a t y o u
w i 1I n e e d . S e n d y o u r c a r b f o r t h i s
work to be done. There will be a
s m a lI c h a r g e f o r t h e s m aI I p a r t s
if they are needed. The 0LD
HR-l8l and HR-I84 are still
K I L L E R C A R B Sf o r s m a l l e r t r a c k s .
These Carbs are still
tlllllIERS
a f t e r t h e y r e c e ' iv e E . C . B L U E P R I l { T
TREATI,IET{T.
S T A G E' 1
If you have a I ittle more need for
S P E E D ,t h i s i s t h e n e x t s t e p a b o v e a
B L U E P R I I I Tw
, ith a dose of T.L.C.
S T A G E' 2
N o w i t ' s t ' i m e t o g o t o t h e F L 0 l { B E I { C Ha n d w e ' r e g o i n g t o g o F A S T E R . T h i s
T n d S T A G Et f T R E A T } l E l lPTt U S s o m e m o r e T R I X
Carb goes thru the BLUEPRII{a
that I'm not going to put down on paper.
S T A G E ' 3 ' O Y E R K I L L T } I I L I G H TZ O I I E '
f oRr t h e D R I Y E Rt h a t h a s t o 9 o f o r t h e
T hi s i s t h e S T A G E0 F C A R B U R E T O
CUST0. GRAI{D
t { A T I 0 l l A L D R I Y E R Sa n d S H 0 P S I i k e J 0 E Y L U I { A T I , J E F F l { E L S 0 l l ,
I . I A R KZ A R I A R I A I I ,R . L . Y . , J I I { R O G E R 0a n d m a n y , m a n y m o r e r e l y o n t h ' i s t y p e
o f u n i t t o k e e p o n c o l ' l e c t i n g t h o s e C H E C K E R EFDL A G S . T h e s e t y p e s o f
c a r b u r e t o r s a r e F U L L B L 0 t { t { ,B U I L T 0 F F T H E B L 0 l f B E t l C H . F o r t h e U L T I I , I A I E
El{O of POtdER
G A I t I S s e n d y o u r R E E DC A G Ea n d C A R B A D A P T O Ro r R 0 T A R YC 0 Y E R
f o r t h e F L O l t B E I { C HT R E A T I , I E IA{ lT{ D A H E A V YD 0 S E0 F T . L . C . A L L E . C . S T A C E
t l t h r u S T A G Et 3 K I T S c o m e w i t h F I L T E R A D A P T 0 R Sa n d E . C . ' K I L L E R ' T R I C K
F I L T E R S . A d v i s e m e o f a n y c l e a r a n c e p r o b ' le m s , I i k e t a n k s o n E n d u r o K a r t s
so that I can make sure you get the right fi'l ter.
All E.C. CARBURET0RS
a l s o c o m e w i t h C 0 I , I P L E TSEE R V I C ET I P S , T U l l I l { GS H E E T Sa n d S H I } l K I T S s o t h a t
you can do your own servi ce and 'KEEP0t{ HII{tlIllc.'
10
olillolson, @.9*4\.
Stat€-of-the-Art
E . C . B L U E P R I l I T P I S T O ]PI O R T
tfalbro Carburetors are used on all
Piston Port Engines and if you're llEI
to the ltorl d of 2/Cycl es , what you need
most is a Carburetor that tunes easy
and i s trouble free.
A good Blueprint
Job by E.C. will fill
all these needs.
S T A G E' I
If you have been in the 2/Cyc1e Class
f o r a w h i l e a n d F E E L Y O U ' R ER E A D YF O R
} I O R EH O R S E P O T I Et hRe, n t h ' i s i s t h e n e x t
step for you.
S T A G E' 2
As you advance in the field of ZlCycle .r',#
Racing, y0ur needs for 1.l0RE
POlfER
increase. hlith a Stage ,2 Carb, it
!
is time for us to go to the FL0tf
B E I { C H . T h e Y E I l T U R Ii s b r o u g h t o u t
t o T E C HS I Z E a n d t h e F U E L F L O t f i s
balanced to the 'increased AIR FL0I.
r e c o m m e n dt h a t w i t h t h i s u n i t y o u a l S O
g e t a n E . C . R A t { F L O t f ' l r l E G AP 0 H E R '
F I L T E RA D A P T 0 Ra n d E . C . T R I C K l 0 o
FILTER.
i
llj"
ir
t..F*
^
w,
t
S T A G E ' 3 ' O Y E R K I L L T I I I L I G H TZ O I I E '
Froma BLUEPRIl{T
t h r u a S T A G E1 2 , u s i n g a C a r b u r e t o r w ' i t h a I i t t l e
t'ime
on it is okay but, when it comes to this Level of Carburetor, we need
to start off with a llEll CARBURETOR.
A n E . C . S T A G Et 3 l l A L B R Oh a s a t o n o f F L O t f B E t { C HT I I 4 E s p e n t o n i t .
The
Y E t { T U R I' i s P U S H E Dt o t h e } I A X I } l U } | . E v e n t h e T H R 0 T T L ES H U T T E RS C R E I fi s
is C A L I B R A T E D
H A I { D } I A D E . T h e n t h e F U E L F L 0 H o f t h e C A R B U R E T 0' R
to f it
t h e A I R F L O I I . A n E . C . R A I IF
I L O } II , I E G A
P 0 t { E RF I L T E R A D A P T O aRn d E . C . T R I C K
l0o FILTER is part of this KIT also.
F r o m t h e E I { T R YL E Y E L B L U E P R I I { T E DC A R B U R E T 0 Rt h r u t h e S T A G E 1 3 T t f I L I G H T
Z 0 t l E A L L U l { I T S C 0 l , l EC 0 } I P L E T E w i t h S E R Y I C E I I { S T R U C T I 0 I { ,T U t { I ] { G S H E E T Sa n d
TRICK E.C. SHII.IKITS.
Thi s i s the TYPE and
STAGE of HALBR0 that
i t takes to t{Iil a GRAI|D
t { A T I 0 N A Lw i t h o r t h a t } r E E K E l { D0 F $ $ $ $ R A C E S . G u e s s t h a t ' s
why most of
t h e I . K . F . a n d l , . JK. . A . F R O I { T R U I { I I E R SU S E E . C . B U I L T C A R B U R E T I O I { K I T S .
If you have any clearance problems like
on an Enduro, where the f ilter
m a y g e t ' in t o t h e t a n k ,
etc.
advise me of this so that I can make sure
that the f ilter
t h a t w e s e n d y o u w o n ' t b e t h e w r o n g s ' iz e o r a n g 1 e .
"KEEP;YA:,##lllililfr
ouillolson,q%9.4\.
Stat€-of-the-Art
R0 0 c c2 / C Y C L EI,I O D I F I EA
Dr L 0 P E l l4 / C Y C L E
H L - 1 A :S U P E 1
i s designed
I atest creation an
T h e a l I l l E t f H L - l A i s T I L L 0 T S O I {L t d . ' s
just for KARTIIlG. As the Carburetor comesfrom Ti I I otson, it is set up
as a gas carb.
For one, as you can see in the
There are many trick parts to this Carb.
picture, 'it has a third jet.
This is needed f or f ine I ine tuning of some
2/cyc'le engines.
Now this same carb can also be had without the third
j e t w h i c h m a k e s t h e p r i c e o f t h e c a r b a b i t c h e a p e r t o b u ' il d a n d t h i s
savings is passed on to the Karter.
W h a t ' is t h e b o t t o m l i n e h e r e ? F o r
the most part there is no need for the third
jet.
The reason is that the carburetor also
has a built-in
m i d r a n g e j e t t h a t R I C H E I { SU P
T H E B 0 T T 0 I {b y i t s e l f . T h e n w h e n t h e m o t o r
get up to peak R.P.M. it
shuts itself
off
As the Carburetor comes it has a
.945 Venturi with a i.060 Shutter.
T h e w a y t h a t t h e H L - i A i s d e s ' ig n e d
you can take it and bore the
Venturi to .980. The 1.060
s h u t t e r s ' iz e c a n s t i l l
handle th'i s Venturi Size.
1 { O I L{ E T ' S T A K E A S T E P I ] I T O
T H E T } I I L I G H TZ O J { E. ..
Let's say that you want or
have the need for a 1.000
inch Venturi.
No problem.
The HL-1A can be bored up
to 1.0?5 or (11/8) and we
can send you a 1.100 throttle
shutter.
Flip the carb over and
rebore the throttle
bore.
For the Engine Builder that wants
to do hjs own thing then we have for you the HL-lA i n KIT F0Ril.
0rder th'i s Kit in Gas or for Alky.
Like all
Tillotson
Carburetors you
can order this
carb which comes from Iil I otson Ltd. al ready blueprinted
and hand pol ished off
the shel f as a gas unit.
0r you can have us carry
it to any Stage that you want from a Stage #1 to 3+3 l4ega Power, set up
to run on GAS 0R ALKY.
As the Carburetor
is set up now
it is
THROTTLE S H U T T E RC A R B U R E T O R
but,
by Spri ng time this same uni t will
a l s o b e a S LI D E C A R B U R E T O R . . .
| ' , H A T ' S T H E B O T T O ML I T { E ? E . C . B I R T a n d T I L L 0 T S 0 t { L t d .
"KEEPS
YAi,#flllillilg
oTillofson,q%S.4.
Stat€-of-the-Art
K A R T I I {AGi l DI / 2 I I I D G E T S A L I I I I T E DZ I C Y C LA
Ei l DO P E I4{ / C Y C L E :
The AllES0l.lH
E 0 R S E P 0 I { EoRf t h i s t y p e o f R a c i n g E n g i n e i s i n D I R E C TR E L A T I 0 t {
R E L A T I 0 Nt o t h e t y p e , s i z e a n d t h e a m o u n t o f A I R F L O L tf h a t g o e s t h r u t h e
t h e C A R B U R E T 0 RT. h e o t h e r k e y p o ' in t i n t h e P E R F 0 R I 4 A I {oCf E t h i s C A R B U R E T 0 R
i s H O LT
f H E F U E L F L O t f I S C A L I B R A T ETD0 T H E A I R F L O I { . W h e n i t c o m e s t o t h i s
this type of Carburetolit's
m o r e t h a n a w e e k s w o r k f o r s o m e o n et o I I A T C H
t hSa t
l l Y t f 0 R K l . l A I { S H I P .T h e r e a r e a I o t o f D I F F E R E T {TTY P E S o f C A R B U R E T O R
are suited for this type of Engine.
I u s e a l l t h e w a y f r o m a 2 8 m mt o a
3 6 m mV e n t u r i C a r b u r e t o r a n d ' i t c o u l d b e a S l i d e o r T h r o t t l e S h u t t e r t y p e
of carb.
There can be a case here that whatever you have for a
C a r b u r e t o r m a y b e f i n e a n d a ' lI t h a t i t w i 1 1 n e e d i s a
For the most part, I prefer
bunch of E.C. 'T.L.C.'
a throttle shutter type of carburetor.
T h e r e a s o n ' is t h a t a s h u t t e r t y p e o f
Carburetor always has a better torque
range than a sl i de carburetor.
0n some
E n g i n e s a 3 4 m mM ' ki u n i i s a g o o d u n i t t o
u s e . I p r e f e r t h e T I L L 0 T S 0 I Io v e r t h e
llIKUl{I mainly because of the ease of
t u n ' in g a n d r e p l a c e m e n t p a r t s a r e a
whole lot cheaper to buy and readily
;eL
avai I abl e.
T h e H R - l 9 l T I L L 0 T S 0 t Ih a s t u r n e d o u t t o
b e t h e K I L L E R C A R Bc o n v e r t e d t o A L K Y
f or the ll2 I.IIDGETS.Thi s carb al so
'is a 'KILLER' torque set up on 0PEll
2 / C Y C L E Sf o r s h o r t t r a c k s .
Move up
t o B I G G E Ra n d F A S T E RT R A C K Sa n d w e
step up the Carburetor Size to an
HR-f9l or HR-190. But it all still
backs up to this:
FITTIIIGTHE RIGIIT
T Y P E0 F C A R B U R E T 0t oR y o u r t y p e o f
R A C I I I Ga n d h e r e ' l t l Y 2 5 P L U SY E A R S0 F
1
E I P E RE
I I { C EI I I L L B E C H E A P E T
RH A I {Y O U R 1
r b .&
IIISTAKES. If you have been
&q
r u n ni n g a C 0 l { T R O L
0 1 { G A Sa n d w a n t
a
t o h a v e t h e B E N E F I T Sa n d P O t l E R
I
:
G A I I { So f a n A L K Y B U R I { E R
then i t' s
't
no probl em f or me to just BLUEPRITIT
your Carb and set it up for ALKY.
A s y o u r R a c i n g a n d H o r s e p o w e rn e e d s
get more demanding, we can move you
u p t o a H I G H E RL E Y E L o f F L 0 l { B E l { C H
D E S I G T { ECDA R B U R E T 0 R I. n t h e 0 P E 1 {
2 / C Y C L E S ,t h e R e e d T r a c k o r t h e
Rotary Valve Assembly has a lot
;$
h
u.b..
t
,l
power gains of
to do with the overall
these motors.
Another point to look dt,
i s t h e F U E LT H A T Y 0 U U S E . I I o v e H O R S E P O I J E R
O U TO F A B O T T L E .
13
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r309 of d charlotte Pk.,Dickson,Tn.
370ss.pl{.61s.446-6t07
14
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olillolson,
f,BP.
3
9
10
1l
L2
13
14
15
16
17
18
19
20
2L
21A
zLB
zLC
zlD
23
24
25
26
26A
27
2'1A
28
29
29x
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DASCBIPTTOX
TrLl7955
TILl ?963
I
ECWPo3
TILl68217
TrL237600
EC010
rrL91A303
TIL91A275
TILl68216
TTLl68247
TTLL6B252
TIL168233
TrL237t54
trL237t41
TrL2372t4
TrL198305
TTLL4162
T r L l 4 13 0 5
TrLt5B422
T r L 9 5 t7 4
T r L g 5 17 0
TrLl68205
TrLg1A351
Welch Plug
Welch Plug
Welch Plug
Diaphragn casket
Diaphragm
Trick Diaphragm
Diaphragn Cover
Diaphragn Cover
Flange Gasket
Flange Gasket
Fuel Punp Gasket
Fuel Punp Gasket
Fuel Pump Diaphragn
Fuel Puurp Diaphragn
Fuel Punp Diaphragn
Fuel Punp Body
Fuel Putrrp Body
Fuel Punp Body
Fuel Punp Body Screv
Fuel SUralner Screen (Brass)
Fuel Strainer
Screen (Silver)
Fuel SLrainer Cover Gasket
Fuel Stralner
Cover (gtue)
Alky Resistant
Fuel Strainer
Cover (White)
Fuel Strainer
Cover (ntacX)
Fuel Strainer
Cover Screv
Idle Mlxture Screw
Idle Mixture Screw
Idle Mixture Scres
Idle Mixture Screw
Idle Mixture Screv Spring
Idle Mixture Serev Washer
IdIe Mlxture Screw Packing
Idle Speed ScreY
Idle Speed Screw Sprlng
Control Lever (Uncapt)
Inlet
Inlet
Control Lever (Capt)
Inlet
Lever Fulcrun Screv
fnlet
Lever Fulcrun Pln
Needle & Seat (Uncapt;
Inlet
Inlet
Needle & Seat (Capt)
Ran Flon Needle & Seat (Uncapt-n)
Ram Flon Needle & Seat (Capt-R)
Ran Flow Needle & Seat (Cap-Afloy)
Ram Flov Needle ONLY (Red Tip)
Ram Flow Needle ONLY (Red Tip)
Ram Flov Needle ONLY (Afloy)
Inlet
Seat Gasket
fnlet Tension Spring
Inlet
Tension Spring
fnlet Tenslon Spring
Inlet Tenslon Spring (Standard)
Inlet Tension Spring (Hard Rate)
Inlet Tension Spring (Soft Rate)
fnlet Tension Spring Shim Klt
T I L 9 1 A 2 51
TIL91A3O4
TrLl5B313
TIL43991
TrL43967
TrL43388
ECIMSO32
ITL2IB449
TIL78A256
TrL44270
TrLt5B297
TrL24B131
TrL155A23
T I L I 5 5 A2 7
TrLl58329
TIL3279
TrL233669
T r L 23 3 6 6 5
4
EC01
EC014A
E C 0 14 8
ECot 2
ECo18
8A
EC01
TrLl6B199
Trr,248323
TILz48299
TIL248345
E C o 01
8C002
EC003
8c998
(Y|
15
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(A
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x
xx
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gIIIIOISOn,
REp. paRT lfo.
IrBscnrpTrox
29A TIL6738
InletValveBody
29BTILl5B343ScrevXXXXXXX
29C TIL237155 InletValveDiaphragn
29D TIL16B253 InletValveGasket
Hi Speed Mixture Screw
30
TIL43987
8C996
Blunt Taperr Hi Flor Alky
Hi Speed Mixture Screv
30A
TIL43988
LongTaperforSensltlveTunlng
EC0l5
TIL43967 HiSpeedMixtureScrer
ECHMS033 Hi Speed Mixture Screv
308
IIL24B449 HiSpeedMixtureScrerSprlng
TIL24B247 Hi Speed Mixture Screr Sprlng
30C TIL78A256 HiSpeedMixtureScrevlfaeher
TIL78A226 Hi Speed Mlxture Screv l{aeher
30D TTL4427A HiSpeedMixtureScreyPaclring
T1L44277 Hi Speed Mlxture Screr Packlng
31A
TIL363517 Nozzle Check Valve
Nozzle Check Valve
EC016
TIL363503 Nozzle Check Valve
TIL3635I7 Nozzle Check Valve
TIL363501 Nozzle Check Valve
TIL363508 Nozzte Check Valve
A4
TIL131592 ThroutleShaft
TILl3l894
Throttle Shaft
TIL132084 Throttle Shaft
Throttle Shaft
EC999
Throttle Shaft
EC999A
Throttle Shaft
EC999B
Throttle Shaft
EC999C
33
TlL292l8
ThrottleShaftClip
TIL29224
Throttle Shaft Clip
Throttle Shaft Cllp
TIL29226
TlL292l8
Throttle Shaft Cllp
34
Throttle Shaft Cllp Lockyasher
TIL7862
35
TILlsCl8
Th.ShaftClipScrer
TILI5B312 Th. Shaft Cllp Screu
TILI5B307 Th. Shaft Clip Screv
TILI5B291 Th. Shaft Cllp Screw
36
TLL24B328 Throttle Shaft Return Sprlng
TIL24B357 Throttle
Shaft Return Sprlng
TIL24B344 Throttle Shaft Return Sprlng
TIL24B38I Throttle Shaft Return Sprlng
37
TIL14407 ThrottleShutter
Throttle Shutter (1.060 O.D.)
TILI4A2
TILI4415
Throttle Shutter
8C995
Throttle Shutter
38
TIL15C29 ThrottleShutterScrer
EC0l7
ThrottleShutterButtonHdScrev
8C994
Throttle Shutter Button Hd Screr
EC994A
Throttle Shutter Button Hd Scrcv
DG4HL
Diaphragn,/GaslretKit
DG5HL
Diaphragm/GasketKlt
RK102
CompleteRebulldKit
RKl03
CompleteRebuild Kit
RK104
ConpleteRebuildKit
BCLK121 E.C. Linkage Kit
ECLRL22 E.C.LinkageKit
ECLK123 E.C. Linkage Kit
ECLK124 E.C. tinkage Kit
16
a s i I t s $ s il B;;
HG|(r)o)ol(vI(vI(n(r)(tlF{H
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X
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X
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X
X
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X
X
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X
X
X
X
X
X
X
x
x
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X
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X
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X
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X
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X
X
X
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X
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x
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X
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X
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Wal brO carburetor
ExplodedView
Ref. No. Part Name
Venturi(mm)
Kit-Repair
' Kit-Gasket
/ Diaphragm
'Ring Screen Retainer
Ring - ThrotlleShaft
"Ring - Packing
Lever - Outer Throttle
Cover -
1
4
6
7
8
9
10
Cover - Fuel Pump
Shaft Assembly - Throttle
Shulter - Throttle
Shaft Assembly- Choke
Clio - ThrottleShaft
16
17
18
19
?O
Swivel Assembly
Shutter- Choke
'Valve - Inlel Needle
Seat Ass'y - Check Valve
Seat Assembly. Governor
'Plug - Welch
'Plug - Welch
Ball - Choke Friction
"Gaskel - M€teringDiaphragm
"Gasket - Fuel Pumo
21
22
23
?4
25
'-Diaphragm - Check Valve
"Diaphragm - Fuel Pump
"Diaphragm Assembly- Metering
Screw - Lever to Shaft
23.83
K1-WB
D1.WB
21-199
21-649
30-753
.1uu
52.514
82-75
92-94
92-149
96-156
96-236
96-245
96-589
3l
Screw - MeleringCover (4)
Screw - ThrottleClip
Screw - Pump Cover (4)
Spring - Needle (ldle)
96-589
34
- Needle (High)
JC
40
41
42
43
44
45
Needle- High Speed
Washer - Packing Ring
'Screen - Fuel Inlet
'Screen - Check Valve
'Screen - Check Valve
102.531
136-106
140-70
46
47
48
49
Pin - MeteringLever
Spacer - Throttle Lever
Plate - Circuit
'Lever- Metering
144-60
1a
38
,o1
96-543
98-160
98-160
Spring - Choke Friction
'Spring - MeteringLever
Spring - ldle Screw
Spring - Throttle Return
Needle- ldle
36
"w
92-185
95-64
95-65
95-515
Screw - Melering Lever Pin
Screw - ldle Ad.iusl
Screw - Circuit Plate
Screw - Throttle Shutler
Screw - Choke Shutter
JJ
AS USEDON THE YAMAHAAND
OTHERPISTONPORTENGINES
16-71
16-75
26
27
28
29
30
JZ
WB-3A
Diaphragm
Carburetor
WB.3A
i
98-192
98-221
98.308
102-152
?rr-ran53
"cart'. Basecasket
,/n
r.r'
W
^-----<
'/\.
t-----.------_?rr-rsl86
,ut-l.fn
A
-((/A
Carb. Spacere'asket
3r-__._
---'- IV
157-585 'Contents in Repair Kit
166.55
"Contents in Gask€t/DiaphragmKit
H B 3 A - W a lb r o C a r b u r e t r o
Kl0l{B - 15 Piece Walbro Repair K'it
D l O t l B - ' l , J a l b r o G a s k e t / D i a p h r a g mK i t
125-512 - Walbro In Line Fuel Filter
E C - 5 5 4 H 8- M e g a F l o w F i I t e r A d a p t o r
(t.r.r.
& tll.K.A. Legal)
E C - 8 4 1 - T r j c k M e g a F 1o w 1 0 0 F i I t e r
(l.K.F. & tlJ.K.A.Legal)
17
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SetsThe PaceFor OthersTo Follow
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.SPECIALT@LS
REOUIRED
TOINSTALL
SEEREPAIR
INSTRUCTIONS
MANUAL
23
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I5s8cAsKETsETl
I T I O R K S !!
B RI G G S S P A R KP L U G
BOOT
PARTNUMBER
BS-280897
20 BS 393812OIL SEAL
BS 294606 OIL SEAL (CRANKSHAFT)
2L BS 66768 PLUG-OIL FILTER
22 BS 93032 SCREW-C.C.COVER
23 BS 297229 FLYWHEEL-MAGNETO
BS 394066FLYWHEELMAG 3-H.P.
24 BS 222698 KEY-FLYWHEEL
25 BS 298904PISTONASSY. (STD.)
BS 298905PISTONASSY..O1O
BS 298906PISTONASSY..O2O
BS 298907PISTONASSY..O3O
26 BS 298982 RING SET (STD.)
BS 298983RING SET .O1O
BS 298984RING SET .O2O
BS 298985RING SET .O3O
BRIGGS& STRATTON
27 BS 26026 LOCK.PISTONPIN
SPECIFICATIONS
28 BS 298909PIN ASSY.
29 BS 299430ROD ASSY.
DISPL.
HP
BORE
STROKE
30 BS 22L890 DIPPER
12.57
cu.
in.
5
2-9/76"
2-7/16"
206.0cc
5
31 BS 22L876 LOCK.SCREWHEAD
65.1mm 61.9mm
32 BS 92296 SCREW-ROD
BS 130232 5 H.P. BRIGGS ENGINE
BS L32232 5 H.P. BRIGGS I.C. ENGINE 33 BS 2 1 1 1 1 9VALVE.EXHAUST
34 BS 26t044 VALVE.INTAKE
35 BS 260552 SPRINGINTAKE VALVE
36 BS 26478 SPRINGEXHAUST VALVE
1 B S 398765CYLINDER ASSY.
37 BS 222443 GUARD-FLYWHEEL
2 B S 297565 CYLINDER BUSHING
40
BS 93312 RETAINER-INTAKE SPRG.
3 B S 299819OIL SEAL
BS 23L84 UPPER RETAINER
5 B S 2LL542 HEAD-CYLINDER
45
BS 260642 TAPPET -VALVE
7 B S 272L57 GASKET-CYL.HEAD
46 BS 212733 GEAR.CAM
8 B S 294L78 BREATHER
52 BS 27355 SM. GASKET.CARB
9 B S 27549 GASKET.VALVE COVER
BS 27909 LGE. GASKET-CARB
1 0 B S 93394 SCREW.BREATHER
BS 295871 PULLEY.REWIND START
56
1 1 B S 66578 GROMMET-BREATHER
57 BS 294303SPRINGREWIND START
L 2 B S 270080GASKETC.C..015(STD)
58 BS 66884 ROPE-REWINDSTART
BS 270L25 GASKET.C.C..OO5
59 BS 230228 PIN-STARTERGRIP
BS 270L26 GASKET-C.C..OO9
60 BS 393152GRIP.STARTERROPE
13 BS 93368 SCREW-HEAD (2 3132)
65 BS 92987 NUT.HEX
14 BS 93369 scREw- HEAD (2 L5/32)
66 BS 399671CLUTCH.ASSY.REWIND
1 5 B S 91249 PLUG-PIPE114''
68 BS 63770 BALL-CLUTCH
1 6 B S 397092 CRANK-DOUBLEBG.
70 BS 298436RATCHET REWIND
BS 397093CRANK-PTOBEARING
7L BS 227653 WASHER-REWIND
BS 230978 CRANK GEAR KEY
73 BS 221923 SCREEN-PULLEY
1 7 BS 9 9 1 5 7 BG-BALL MAG SIDE
17ABS 9 9 1 5 8 BEARING-BALLPTO SIDE 75 BS 220865 WASHER.SPRING
76 BS 68238 WASHER-RATCHETSEAL
1 8 B S 298204 c.c. covER (130232)
BS 297602 c.c. covERA(130202) 90 BS 397135CARBASSY.(NEWSTYLE)
BS 299437 CARBASSY.(OLD STYLE)
1 9 B S 297603 BUSHING-C.C.
COVER
95 BS 93499 SCREW-TH.VALVE
20
96 BS 2Lt203 THROTTLE.CARB
97 BS 2992t2 TH.SHFT & I,EVER
114BS 66594 GASKET.NEEDLEVALVE
11 6BS 65978 PACKING.NEEDLE
11 7B S 230590NUT-NEEDLE VALVE
1T8BS 23433 VALVE.NEEDLE
124 BS 93357 SCREW-HEXHEAD
127 BS 22831 PLUG-WELCH
r47 BS 230591SEAT-NEEDLE VALVE
148BS 22235 WASHER-NEEDLEVAL
149 BS 26336 SPRINGNEEDLE VAL\M
152BS 260575 SPRINGTHROTTLE ADI.
154BS 93527 scREw RD. (5-40X 5/8")
163BS 27rr39 GASKET.AIR CLEANER
166BS 23r332STUD.AIR CLEANER
180BS 397137FUEL TANK ASSY.(NEW )
BS 297600 FUEL TANK ASSY.(OLD)
181BS 39481,8CAP-FUEL TANK
190BS 93440 SCREW.FUELTANK
191BS 271592 GASKET-FUELTANK
2OOBS 22t480 GUIDE.AIR
202 BS 260678 LINK-THROTTLE
203 BS 3 9 3 9 1 9BELL CRANK & BUSH
205 BS 93838 SCREW-SHOULDER
257 BS 93543 SCREW-FIL.HD. SEM.
304 BS 398345HOUSING BLOWER
305 BS 9 3 1 5 8 SCREW-BLOWER
306 BS 22t'tl SHIELD-CYLINDER
307 BS 93490 SCREW.CYL.SHIELD
BS 93042 SCREW-CYL.SHIELD
308 BS 22L5t2 COVER-CYL.HEAD
333 BS 397358ARMATURE GROUP
334 BS 93613 SCREW-ARMATURE
335BS 93414 SCREW-ARMATURE
346 BS 93705 SCREW
357 BS 9 1 5 3 9 KEY
358 BS 3 9 7 1 4 5GASKETSET
392 BS 260455SPRING-F.P.DIAPH
394 BS 270026 DIAPHRAM
432 BS 221377 CAP-SPRING
433 BS 93265 PIN-DIAPH.COVER
434 BS 2 1 0 9 5 9COVER-DIAPHRAM
435 BS 9 3 1 4 1 SCREW-DIAPH.COVER
445 BS 396424 CARTRIDGE.AIRFILTER
446 BS 395642 BASE.AIRCLEANER
467 BS 2L2706 KNOB.AIR CLEANER
526BS 93343 SCREW-TANKBRKT.
535BS 271466ELEMENT-AIR CLEAI{ER
608 BS 390463 STARTtsRASSY.REWIND
609 BS 260694 SPRINGTI{ROTTLE LINK
611 BS 391813FUEL PIPE & CLIP ASSY.
612 BS 296811PIPE.FUEL
634 BS 270L67 WASIIER.TH. SI{FT. FELT
635 BS 280897ELBOW-SPARKPLUG
642 BS 223306 COVER.AIR CLEANER
655 BS 222598 A}ICHOR-SPRING
68T BS 299060 NEEDLE VALVE KIT
74T BS 262060 GEAR.TIMING ( BRG)
852 BS 396397 CLEA}IER GROUP-AIR
871 BS 63709 GUIDE.INTAKE VALVE
978 BS 271736 GASKET.OIL SWITCH
987 BS 398970 SEAL.THROTTLE SHFT.
SPECIAL ITEMS
BS 220624 TIIRUST WASHER -CRANK
BS 220884 SToP SWITCH
TOOLS
BS 19165 FLYWHEEL PULLER
BS 19167 FLYWHEEL HOLDER
BS 19230 PISTON RING COMPRESSOR
BS L9244 CLUTCH WRENCH
BS K114 CLUTCH WRENCH
BS K64
VALVE SPRINGTOOL
BS K311 VALVE LAPPING TOOL
BS L233OOVALVE SPRINGCOMPRESSOR
BRIGGS I/C ENGINE USES THE SAII{E PABTS
AS THE #I3O23251O2, D(CEPT THE FOL.
LOWING
I
lA
25
25A
258
25C
871
34
85393839
89195133
85393819
8S393820
85393821
85393822
85262001
BVS26O8@
CyltnderAssembly
DualBearing
CyllnderAssembly
Tello-bushtng
PlstonAssembly
Std.
PtstonAssembly
.010O.S.
PistonAssemHy.020
O.S.
PlstonAssemHy
.030O.S.
ErhaustValveGuide
Exhaust
Valve,Stelite
A[S0
DISCOUilTBRAIiI SURGERY
Pl{ot{E# 615-116-6t07
BRIGGS& STRATTONREPAIRTOOLS
Part
No.
19051
19055
19056
19057
19058
19061
19062
19063
19064
19065
19066
',9069
19122
19151
19165
19167
19191
19203
19230
19244
Ocgcrlptlon
SparkTesier
Br€akerPlungerGauge
PlungerBushingCount€rbore
Reamer
PlungerBushingDriver
PlungerBushingFinishReamer
Screwdriver,
Carburetor
Screwdriver,
Carburetor
ValveSpringCompressor
ValvoGuidoBushingCounterbore
Reamer
ValveGuideBushingDriver
ValveGuideBushingFinishReamer
FlywheelPuller
ValveGuideRejectGauge
ValveGuideRejectGauge
Flyrvheel
Puller
Flywheel
Holder
ReamerGuideBushing
FlywheelPuller
RingCompressor
StarterClutchWrench
9
1COtl
19099
't9100
19101
19123
19124
19166
Dcrcrlptlon
PilotGuideBushing
FinishReamer
Pilot
PilotGuideBushing,
BallBearingCover
Counterbore
Reamer
ReamerGuideBushing
ReamerGuideBushing
SupportJack
BushingDriver
PlugGauge
\7
=aQr"
reo66
1a055 lolgt
19203
w
alEt005t
\-
1C057
190G9
r9203
E
1905t
trf-
5
LJYH
BF==
r00c2
190G1
[f
a
ttl22
=
19t5t
't0230
6 w
10rc5
r90ca
teo.s
MAINBEARINGTOOL KIT
Psrt
No._
19094
19095
19096'
19097
__5;>
G
er
l'oea
./R
t^l r
toll
-\
\Jrreoea
@
190c5
I
tFl-l
[Ft90|e
o
r $t7
@ CI
re'r00
r$0'l
Er0raa
TOOLSNOTSHOWN
E . C . S P E E DS B C R E T S
B . C . B L U E P R I N TM A N U A L
B / S M O T O R S. - T ' I L L O T S O N
DIAL CALIPER
DIAI, INDICATOR
VALVE GUIDE PULLER
E . C . P R O D E G R E EW H E E L
D E G R E EW H E E LA D A P T O RK I T
VALVE GUIDE TOOL KIT
E.C. FINISH REAMER
EX. FINE LAPPING COMPOUND
VAL. SPRING COUPRESSOR
(LrMrrEDS & oPENS)
O P E NB R I G G S , B I G V A L V A
S E A T I N S T A L L A T I O NK I T
( T N T A K E& E X H A U S T )
22
VATVE & LIFTER GAUGE
LAPPING BLOCK
P R O C Y L I N D E RH O N E K I T
T O R Q U EW R E N C H- I N C H L B .
VALVE SET CUTTER
VALVE SPRING COMPRESSOR,
8.C.
sPooN, Box sTocK
=Tv9
Tools
PoRTTNG
7
,/.t:
v
u:t
2'
i19
Controlledspeedwith lull powerat any RPM is the secret- 0 - 20,000RPM. When workingwith
aluminumyou can workat slowerspeedsto reducemeltingof the metalin yourcuttingtool.A special
"teedback"circuitassuresthat no poweris wasted,and usesonlythe electricityrequiredfor lhe torque
you need.
HANDPIECES
t..Q
1MC
XN[tsEruS III
qtPrlr
T'
T h e N o I M C r s o u r n g h t a n g l e h a n d p r e c eb u r l i t o d o t F b 1 o b T n e h o a d c a ^ b e
g l r y r v g l et od a n y a n g l e ,a t s ot e l e s c o p i c a l ley x t e n d € du p t o 4 H a n d p r € c ar s a v a r l a ble wrth both 3,32 and 1 S collet (3/32 collot supplrodunlossoiherwrse
s o e c rrf 6 d ) C o m e sw r t h t w o s p a n n e rw r e n c h e sf o r t r g h t e n r n gt h e t o o a sI n l h e c o l l e l
TlT *I
ET*I
rllls
IIr *t
fl)
tl
gt
rryTqIr(x
t3
2MC
rlll
1
11
*r
rl
1
I
I
I
I
I
I
1
I
I
L ea, 3/32 shank 3/16 head,eUtptlcat
burr
I ea. 3/32 shank 3,/16 head, tree b.u'r
44O collet
6et for 44,C ttandplece,T
colletsrl,/16
to ln - 1/32 lncrenarts
FIB-4 Buffs - 10 felt poushirq
Buffs
e-27 Stones - 3/4" dLa. x 3/32, flts l.t-l
!.tandrel
G-28 Stones - 3/4tt dLa. x 1/8, flts l,t-l
It{andrel
C-29 Stones - 3/4,' dla. x l/32. fits l't-l
l'fand!el
D-2 Ort off rheels 1l dia. for t+l t€ndrel
WL !,tandlel - 3/32 stlank for l/16" arc.
hole slze
I.'l-3 }€ndrelr
3,/32 shank threaded end
0i1 cc-10
Grease CC-ll
rl
1
rl
10
l0
l0
44
New brg rght angle handptece even larger than the lMC tdeal lor reachrng deep
Into lhe translers on lhe larger bore brkes (250 CC & large{) Handlesr.. &r/t shank
tools 3 32 collet also avarlable
Dc26 - t" shank eulptlcat,
calblde burr
RC26- l" shank, tree 3', long c?rblde burr
sp€ciar l,tandrer - t" 6lEnl( sM-14 for uElrq
etlpry, steel woo1, ebc. for high lustre
polishing
2
lll
ltl
3MC
I
1
1
I
11
1t
Desrgned wtlh larger beanngs and one prece shatt lo hold close tolerance. especrally desrgned lo accommodate long shank carbtde and heavy loadrng Handprece has sealed beailngs wrth dusl covers and comes wrth grecrsron la collet
Collels t/16 3132 1lS 3116 114
{unfess otherwrse specrtred)
Rl'C lbtor $lth Ball Bearings & Foot
Control, Fle)( StDft
44[ l{andplece
7|C Handpiece
5aC lrandplece
U,lC Handplece
5O'rCStone Set 3/32 StEDk, 13 ass,t.
shapes for fast cutting ln st€l
10OI,CKit - 10 asa't. burra for
5714C
llol,C Kit - 10 stsres for 57C
12OC Kit - 72 rubber abraslvee yittr
nEndrels
5
2
6
I
I
roptlonal rdt} 44AlC or AO H;andplece. l,hen ordering
Ilandplececodt 441.{CA 440 Collet set.
'Q';\\jf
57MC
The No 57 MC rs a new swrvel-head handprece thal can be locked rn one of rl0
d r l l e r e n t p o s r l r o n s F o r l r g h t c u t t r n g . p o l r s h r n ga n d t r n a l l r n r s h w o r k I n t h e m o s :
rmpossrble places {Handprece takes onty 332 tatch-fype accessoiles) Lubncalron requrred
CARBIDE
BURRS
AH SOOR
s250R
Sg/5R
AH25OE
AH3r/5E
AH5OOE
s2s0E
Sr/5E
\-*\
^ppRoxru^rE
ov€R^LLLENGTH
2yr.'
Head Ola.
1t4
3/8
1t2
cuTs
1t4
3r/8
'r
1t4
3/8
1t2
FOUt{O
114
3/8
AH25OT
AH3r/5T
AHsofi
1t4
3/8
1t2
s250r
1t4
3/8
sr/sT
^'KEEPS
-
The No. 44MC is for all generalwork with shank sizesup to 314".No lubricationrequired;greasesealedballbearings.Comescompletewith pin and wrenchfor changing collets(1/4"unlessotherwisespecitied).Purchaseol compleiecolleclset (# 440)
is recommended.
AH25OR
AHr/5R
PortlngWsr. Lubricatesand helps prevent
"loadingin carbidecutters.Prolongscutter
!v
2LBs.pw.16
'bYY'r'r
44MC
Tool No.
AO
r(GEsnrEs
ilDTIKISL
1,/8' $ank left Hand Burrs
3/32 Shank 3,/16 Head R,E & T
1,/8 Shank 3/16 Head R,E & T
#93 FlodbLe Inner Shaft
*77 outer Sheath
*119 lbtor Brushes
#1026? Bendr lYpe Mcbor Stand
*40008 Buffing & Potlshing Ccrnpound
'lFs,-f
7MC
T h e N o 7 M C r s o u r m o s t v e r s a t r l eh a n d p r e c e t o r l r g h t w o r k T h r s h a n d p r o c e t a p e r s
downtoonly3,l6
drameter.allowrngoperatorloworkrnconfrnedandlnacc€sstble areas Has a unrque push-9ull collel closet lor qurck changrng ot lools
(Handnrece lakes 332 shank accessoles only) Lubrrcatron requrred
% ' ' S H A N KD I A .
*A"-.n{t|l
YA
qw
€
ELLIPIICAL
fr,tn
nn
],,'ll
-f
ta? al
TNEESHAPE
scorTrECAGLE
rtpt_LAsnNA^X.;irNrrNc
Rt. l, Box 306
rremingway,
SC ZgS54
nwY.4l $su3h
r-onstruction,
[,oggi"g CE.L.
Eguipment
,B,u., 55g.2332
nome:
S2Z.ZgOl
546.836?
€g
=*.*ru'b*-Dry::^,&"il1
r
*f
P:
n-4-o, 6<o^^r:[^T^,
h"5^;u"
mo"a"r-/
t1tr
4*&
ta5,Ge^;'
ffiJ^U,
24 4"htu"W
ENTRYLEVELRACING:
BRIGGS
and
STRATTON
Story By E.G.Birt
9ack in the mid 50'sthe firstGoK a r tw a sb u i l t .N o o n e a t t h a t t i m e
lot Racer
thatthisfirstparking
dreamed
wasthe birthof a newsoortof small
fourwheelracers.lt waslikean explosionthatshookthe world.Almostover
nightthefeverof the smallfourwheel
racers
affected
oldandyoungalike.Ridlot soongrewoldand
ingintheparking
longracetracksstartedshowing
before
uplikenewgrassin the Springtime.
withthe racetrackscamecomAlong
petition.
andracingclubs,rulesof competition
were
andracingassociations
formed.
Overnight
whathadstartedin
lot hadgrownintoa world
theparking
widesportof smallopen4 wheelracinthelate60's
ing.Dueto theeconomy
andearly70'skartingtooka downhill
Hard
fall,andwentintoa bitof a slump.
coreracerskeptthefirelit thoughand
inthelate70'skartingstarted
theclimb
backup.Forthepast10 yearsno mot o r i z esdp o r th a ss e e ns u c ha c o m e
We'relookingat a
backas kartracing.
plusgrowthfactornowandthisis
3070
knowsandsees
onlythestart.W.K.A.
work
this,andouroowersin command
longhardhoursdayin anddayout to
makethis associatron
wherethe newcomer
canget intothesportof karting
without
beingoverthetop of hishead.
havebeenputin for pops
Newclasses
classstructure
over40, andourRookie
makes
thisa truefamilysport.So,all
youoldracecarandmotorcycle
racers
nowhavea placeto go.Youdon'thave
t o b e t h r o w nt o t h e y o u n gl i o n st h a t
havereaction
timefasterthana cat,
andtheeyesof aneagle.Plusrt'slegal
in thepits.So icedown
to drinkGeritol
thechestandlet'sgo racingat anentry
level.
Nowyouhavea choiceof whatkind
of a classyouwantto startin, 2/cycle
or 4/cycle.Themostobviousplaceto
startis at the bottomandworkyour
wayup.lt doesn'tmakegoodsenseif
youare40 plusandstartwithanOpen
4/cycle,or an Unlimited
2/cycle.lf you
try this youare goingto findyourself
s p e n d i nm
g o s to f y o u rt i m ep i c k i n g
LE6NL
CHEAT
2 ANO 4 CYCLERACERS
CUT .1 TO .4 SECONDS
OFF
YOURLAPTIMES.LOOKING
F ORT H E HOTTIP ON HOW
TO CHEATLEGAL?
PRO-TEC ir r nsw !p!ce
age Anli-F.iction M!trl
Trotmgnt thrl it r pctrola
um-baled Producl rp&irlly
lormslstgd lor u$ rith lny
Dctrolrum b6!cd lub.icant.
ninlral o( lynth€tic. PROTEC Anli-Friction Motrl
Trestm6ht lcturtly tGltr th.
mtirl lur|lc6
whrrcEr it i!
usod. PRO-TEC wlll redu6
friction ol moving motal p!rt!
40 to 759t. Dyno t6t rclult!
lrom ls8ding ric! c!. lngin€
build.rg lhow nrl grin! in
hoB€pow€r !l much at 1096.
You cln tllo b&omo I
PBO-TEC Oiltributor. PROTEC th€ wry lo pul your kart
in lha win^er! circle
wp
C.ttlog of GO-FASTEFtRlx
S.nd 15.(D lor Crt|toe
N. ctlt$roTrE sT
AOX F,IST
DICKSON,TEilN.
J7O55
(6!5),fi6-6807
Our 25 years experienceis
cheaperthan your mistakes.
25
Photos By: Jon Brogden
yourself
out of the fencesandcollectinghaybales.
At thispointandtimeI'massuming
that the 4/cycleclassesarethe most
popular
classes
rnyourareaandthisrs
the motorthat you havedecidedto
startwith.So for part#1 of entrylevel
racingwe willcoverBriggsandStratton,andI willfollowup withpart#2 on
theUS-820.
At the entrylevelit makesno differor 40
enceif it's an 8 yr. old Rookie
pluspop,needed
for a a baknowledge
sic set up Briggsengineis thesame.I
wishedthatit wasas easyto do as to
say,just buya motor,or stealthe one
off the tillerandgo racrng;but it's not
q u i t et h a t c u t a n d d r i e d .T h e r ea r e
somethingsthatyoumustdo to set
t h e m o t o ru p t o b e l e g a la n d r a c e
ready,
Inshortbasicblueprinting.
At thispointyoucanmakea choice,
youcanlookthrough
ourTechManual,
pickout a Horsepower
pick
Merchant,
dialthe phonenumber,
up Ma-Bell,
and
tell himwhatyouwant.Fromtherehe
willworryaboutyourproblems
andyou
T.V.0r you
cango backto watching
canreadon withplansof gettingyour
handsdirtyandburning
somemidnight
oil,anddo yourownthing.Beforeyou
c a nc a r r yo u t t h e b e s tl a i dp l a n so f
miceandmenyouaregoingto haveto
havea fewspecial
toolsandtheknowledgeof whatto do withthemafteryou
havethem.SeePhotos
#2. 3. & 4 and
list.Nowcomesthe hardpart,I'mgoingto try andteachyouwhatto use
a n d h o w t o , p l u sh o w t o g e t y o u
throughthe TechBarnafteryouwin
y o u rf i r s t r a c e .E X I TR I G H TS, T A G E
WORLD KARTINGMAGAZINE/NOVEMSER 1990
Specia/
too/sneededto do a Briggs
and Strattonblueprint
andmajorreburld.
I N S I D EL I N E
LEFT:
Let'sassumethatyouarestarting
off witha brandnewmotor.Nowa new
motoris notthebestto builda raceengineout of. So let'smakea usedengineoutof it undera controlled
wayso
as notto hurtrt. STEP#1, SeePhoto
#5. Takeyounewmotorandpullthe
b l o w e cr o v e ra n dc y l i n d ehr e a do f f .
Nowtakeyourdialindicator
standand
indicator
andboltit to the too of the
block.Placethe indicator
overthecenter of the piston.Liftup the indicator
stylettandplaceyourtoolsteelstraight
edgeunderit overthetopof theblock.
Putthisstrarght
edgeon the sameline
as thecrankshaft.
Nowsetthedialindic a t o r f a c e o n z e r o , r o t a t et h e
crankshaft
over,andletthepistoncome
up andovertop deadcenter(T.D.C)
lf
the pistonliftsthe indicator
up more
than.005youhaveproblems;
because
t h i si s t h e l e g a m
l aximum
a m o u not f
pistonpop up thatyoucan haveand
stillget through
the TechBarn.Hopefullyyouhavemadearrangements
with
whoeveryouboughtthemotorfromto
returnit for another
onethatis legal,or
youhavea buddythatneedsa motorto
builda LimitedModified
out of. lf the
blockmakesthisfirstTechcheck,write
downwhateverthe pistonpopup is. lf
the pistondoesn'tcomeup to thetop
of the blocklet'sfigureouthowmuch
i t ' s i n t h e h o l e .S e eP h o t o# 7 . M o v e
yourindicator
andstandoutof theway.
Nowtakeyourstraight
edgeandlayit
onthetopof theblocksamelineasthe
crankshaft.
Nowtakeyourfeelergage
apartanfindthebladethatis theright
thickness
thatit takesto layon top of
the pistonandjustlet youturnthemotor overT.D.C.
Thiswillgiveyoua close
i n t h e h o l em e a s u r e m eN
n to. ww r i t e
thisnumber
downinyournotebook.At
t h i sp o i n tw e w i l la s s u m teh a ty o u r
blockis legalandwegoto Step#2.
Let'sremove
thefueltankandcarburetor,leavethemas an assembly,
also
remove
the valvebodycover.Onceyou
h a v et h e s ei t e m sr e m o v e yd o u a r e
readyto takeyourvalvespringcompressorandslipthe littleforkbetween
the springandthe lowerretainer.
Compressthe springandremove
the valve
springretainer.
Remove
bothvalves
fromthemotor.Nowoullthesidecover
gear,Look
off andremove
thegovernor
a t t h e i n s i d eo f t h e s i d e ' c o v er e
r al
close.At the bottomof the pinthatthe
g e a rj u s tc a m eo f f o f t h e r ei s a f l a t
washer.
Thiswasher
lookslikepartof
it now.lf youforget
the case.Remove
andleavethiswasher
onthepinit'sgorngbe a baddayat BlackRockwhenrt
worksits wayoff withthe enginerunning.Thegovernor
armitself(thingthat
hasa flat paddleon the endof it) cut
thispartof so thatallthatis leftis the
pin,Nowputthispinbackintothecase
to fillbackupthehole.Don'tforgetthe
c l i p .L e a v et h e o u t s i d ep u l la r mo f f .
m
11.000inchdegreewheel;
better
knownas a 2:00in themorning
wheel.
Nowput the sidecoverbackon and
torquethe boltsdownto 80 inchlbs.
Workyourwayfromthe middle
to the
outside
edge,andin 10 inchlb.session
till youget to 80 inchlbs.Thistakes
careof Step#2.
youcancarNowyouhavea choice,
ry yourblockto a goodkartshop,or
sendit to oneandhavethemputvalve
guidesin for you.0r youcanreadon
I knowwhat
andlearnto do it yourself.
you arethinking.Whyarewe putting
valveguidesin a newmotor?
Theycan't
be wornout.Themotorhasonlybeen
put througha start up by Briggsand
Fairquestion.
Reason,
Stratton.
Briggs
andStratton
madea tillerengine,
nota
raceengine,
andsincethismotorisgo
ing to be askedto do alotmorethan
digtattersat 3,600R.P.M.
let'sgiveita
chanceto liveanddo it'sjob wellasa
raceengine.
BriggsandStratton
usea
guide
specialstainless
steelexhaust
:.
iHi q )
a;
lJ-
Ft
rrt
v
r't
o
o
O
j.
o
1U t AU
FP:n.?
0
=6
I
crf
E
gL
0
\
l\
q
8i
?o
->
i n EF 2
5HluJ*
(5\
I
o.E
Bk
o
\
CD .2
o
o.\
ri
L:
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ffi
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c.!
C:
3E \oh
t'r
:
=,r Eg
3s
ci
o;,
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N
t
T
{
o
-,
Y
a
gurdeinstallation
Valve
reamers
and
drrvers.
26
WOBLD KARTINGMAGAZINE/NOVEMBER 1990
HL - 348
u.s.A.
7ilIO6On,
BOLT. ON
WINNER
HL- 355
BOLT I ON
HORSEPOWER
FOR MODIFIED BRIGGS and OPEN CLASSES
FLOW BENCH DESIGNED AND BUILT
BY TILLOTSON LTD.
F O R S U P E RS T O C K ,L I M I T E D M O D I F I E D
W. K. A. AND I. K. F. LEGAL
A YEAR of RACE WINNING proves
the FLOW BENCH DESIGN of this
RACING TILLOTSON CARBURETOR is
SUPERIOR for these classes.
SPECIAL machined INFINTE RADIUS
VENTURI and THROTTLE BORE
assuresyou MAXIMUM AIR FLOW,
FUEL METERING. and HORSEPOWER.
{l
FLOW BENCH DESIGNED AND BUILT WITH
LARGER VENTURI and THROTTLE BORE
TO SUPPLY THE EXTRA AIR FLOW and
FUEL NEEDS of these OPEN CLASS
MOTORS. The HL- 355A. is not just a
BORED OUT HL-348A This is a ALL
NEW FLOW BENCH DESIGNED CARBURETOR
WITH INFINTE RADIUS VENTURI, and a
1.060THROTTLE VALVE. RACE TRACK
PROVEN and the TILLOTSON you've always
wanted. YES, 2--CYCLES LOVE IT TOO.
N
{
My 25 plus yrs. Experienceis cheaperthan your Mistakes.
Distributor& Dealer ProgramAvailable o Send 5.00 for Gatalog
s
Tillo(gtt"u.
s.A.
N. Cll/tRlOTfE ST
D|CKSON,TENN. J7055,
PA|2NE (6.15)rf6-68o7
T
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Fi#gFEgEEiFFF
FgFigffEiEigFF:iiFFigiEi
A s y o us t a r tc u t t i n gt h e g u i d ea p p l y
e a k i n gs u r et h a ty o u
e v e np r e s s u rm
don'tpushthe reameroverto the stde
a s y o u a r e c u t t i n gA
. f t e ry o u h a v e
reamed
the holeto the deothneeded
or anyoil
takea QtipandsomeM.E.K.
freecleaner
andcleanoutanychipsin
thehole.Nowtakeyournewguideand
lookat theendsclose.Youwillseethat
theyareverysharp.Takea smallfile
andfile a chamfer
on the endof the
Thiswillgiveyoua leader,
and
bushing.
in straight.
helpyouget the bushing
Nowtakethebushing
andputit onthe
endof thedriver,
andtapthenewbushingintothe hole.Note:lf youfindthat
the holewenta bit big on youandthe
guidebushing
dropspartwayintothe
holeby rtself,stop.Pulltheguideback
o u t . Y o uh a v e n 'l to s t t h e b l o c ky e t .
andthegoverSidecoverremoved
good.
Cleantheoutside
of thebushing
gear
must
removed.
nor
that
be
T h e nt a k ea s m a l lp u n c h( l e a v et h e
I N S I D EL I N E
bushing
on the endof the driver)and
puta bunchof smallbumpsontheoutNowputsomered
Thiswill sideof thebushing,
thanthelengthof thebushing.
on the outsideof the bushing
all Locktite
assureyouof gettingthe bushing
thewayin plusgiveyoua placefor oil andtap it intothehole.lt willlockinto
to be trappedandlubethevalvestem. place.Moveoverto the intakesideof
Ihisis a flatwasher
thatwillgetyou
intotrouble.
theblockandcarryoutthesamesteps
here.
Nowyournewguidesarein. lf the
valveswon'tslideup anddownin the
guidesfreelyyouwillhaveto runa finthe guide.Forthis
ish reamerthrough
I usea reamerthatis justa
operation
tick biggerthanthatof the valvestem.
for
Briggssaysusea I/4 inchreamer
this;but I don'tbuythis.Whygo to all
the troubleto put in newguidesthen
But
cut the sloprightbackintothem?
theyaremakingtillermotorsandyour
IillOtAn HL-348
The lilinningest Decision You'll Ever Make,
W.K.A. ,I.K.F. ,Legal, Super Stock,Limited Model.
Over 1 Year of d€velopmenttime and Top ol The Claes.
The HL-348A Carburetor is Technology ol Tomorrow
For The Racer Today.
IiIloSar
WALBRO
t'*\f,.*
DTIKUIII
4lCycle
& 2/Cycle
Carburetor'!
And
Original
Service
Parts.
t
FIf,trylED
Carburetor'g
"When Winningir
Everything".
Distributor& DealerProgramAvailable
Send5.00for Catalog& information.
N. cHtRt,TrE sT B,x FrsT
DtcxsoN, TEHN.)7055, Ph(,NEGrj) rt6-6807
M y 2 5 p l u s y r s . E x p e r e i e n c ies c h e a p e rt h a n y o u r M i s t a k e s .
'
28
WORLDKARTING MAGAZINE/NOVEMBEB 1990
ersbackonthevalves.
Thisblockhas.004 pistonpop-up.
INSIDELINE
building
a racemotor.
At thistimedon'tworryaboutlappingthevalvesin. Theseatshaveto
Dound
downandbackto thefirststatementwe want'toprotectthe narrow
seats.
Soat thistimewe don'twantto
totakeoffsomething
thatwemayneed
later.
Nowpullyourtapeoff andputthe
springs
backintothespringwell.Short
spring
withcoildownontheintakeside
a n dt h el o n gs p r i n go n t h e e x h a u s t
side.Coatthestemsof yourvalveswith
a goodcoatof greaseor leadplate.I
grease
likePro-Tec
for thisjob.Nowslip
thevalves
backintotheirholesandwith
yourspringcompressor
compress
the
springs
andputthelowerspringretain-
Withthevalves
backintotheirolace
putthe valvebodycoverbackon. Put
theheadbackon andtorqueit downto
140 inchlbs.Putyourcarbandtank
assembly
backon andthe stockmuffler.Laststepis putthe blowercover
backon.
At thispointyoushouldhavethemotor all backtogether
withthegovernor
removed
andthe newvalveguidesinNextput 16 oz. of a good30
stalled.
weightoil in the motor.I recommend
a
goodoiladditive
mixedintheoilforthis
breakin oil.Nowturnthemotoruoside
downso oilwillcoatalltheupperend.
Nextboltyourenginedownon the motor mountandboltit backon the kart
so youwill havesomewayto holdit.
Next,geta gascanandgo geta gallon
of gas. lf you don'thaveanyat the
housestopat the locallawnmower
shopand get some?/cycleoil. You
need4 ounces.
lt doesn't
makeanydifferencewhatkindof 2/cycleoil you
use.Nowputthisoil in yourgas.We
wantthe 2/cycleoil in herefor top end
lubefor ournewguidesandthe upper
endof the engine.
Fillthe gastankup
and set the mixtureneedleat I I/2
turnsout.Besurethatyouputa spring
on thethrottleso thatyouwon'thavea
runawaywhenyoustartthemotor.Fire
theengineandsettheidleandmixture
so thatthe motoris running
at a nice
smoothpace,notlugging
its heartout
or revingits brainsaway.Nowlet the
motorrun 30 to 40 minutes
likethis
thenshutif off for 30 to 40 minutes
to
coolout.Keepthisuptillyouhaveused
upthefullgallonof gas.ls thisgoingto
Markon valveguidereamer
soyou
howdeeptogo.
willknow
t a k es o m et i m e ?Y o ub e t , a b o u t8
hours,maybe10. BriggsandStratton
madea gasmiser.Butdon'tcheatand
cut this ooeration
short.Yourrewards
aregoingto be a fasterengine
andone
Romewasn't
thatwilllasta lot longer.
builtin a day.Nowyouarestartingto
figureoutwhyanengine
builtby a good
engine
builder
cancostas muchasfive
timesoverthe windowstickeroriceof
the motor.lt all comesdownto time
andeffortspent.
butdue
Sorryto leaveyou hanging;
Tech,
to the sizeof your 1991W.K.A.
Manualthisyear we haverun intoa
Part#2 andthewindup
spaceproblem.
willcomenextissue.ThewayI haveit
figuredoutby the timeyou haveyour
December
lssueln your handsyou
shouldhaveyourmotorbrokenin and
cleaned
up.
TechEd.
E.C.
PRO-TECMETALTREATMENT
P R O - T E Ci s a s p a c ea g eA n t i - F r i c t i o nM e t a lT r e a t m e n t h a t i s a p e t r o l e u m - b a s e d
p r o d u c t s p e c i a l l y f o r m u l a t e d f o r u s e w i t h a n y p e t r o l e u m - b a s e dl u b r i c a n t ,
m i n e r a l o r s y n t h e t i c . A s t h e n a m e i n d i c a t e s ,P R O - T E C A n t i - F r i c t i o nM e t a l
T r e a t m e n ta c t u a l l yt r e a t st h e m e t a l s u r l a c e sw h e r e v e ri t i s u s e d . l t i s n o t a n o i l
t f m e t a ls u r l a c e s .P R O - T E Cw i l l
additiveb
, u t a s p e c i a lf o r m u l af o r t h e t r e a t m e n o
r e d u c e f r i c t i o n o f m o v i n g m e t a l p a r t s 4 0 t o 7 5 0 / oi s; e x c e l l e n tl o r n e w e n g i n e s ,
p r e v e n t s b, r e a k - i n" s c u f f i n g "a n d e x c e s s i v ew e a r .D y n o t e s t r e s u l t sf r o m l e a d i n g
r a c ec a r e n g i n eb u i l d e r ss h o w n e t g a i n si n h o r s e p o w ear s m u c h a s 1 0 0 /aon d w h e n
i n l e c t e di n t o w h e e lb e a r i n g sa n d o t h e rm o v i n gp a r t s ,r o l l i n gf r i c t i o ni s r e d u c e db y
, hen
2 5 0 / 0T h r e ey e a r so f k a r tr a c i n gh a s p r o v e nt h a t P R O - T E CM e t a lT r e a t m e n tw
u s e d i n 2 - c y c l e sc, y l i n d e rc l e a r a n c ecsa n b e t i g h t e n e du p e n h a n c i n gc y c l i n d e r
s e a la n d f a s t e rl a pt i m e s .A l s oa d r o p o l 5 0 0 /aon d m o r ei n w e a rt o t h e m o v i n gp a r t s .
4 - C y c l e r a c e r s , s t o c k a n d o p e n s , h a v e r e g i s t e r e dr e p o r t s a l l t h e w a y f r o m
w r n n r n gr a c e s w i t h n o o i l l e f t i n t h e m t o o n l y a d r o p . W e a r f a c t o r s a r e
u n b e l i e v a b l ec ,a m w e a r a n d v a l v et i m i n g s t a y sw h e r ey o u p u t i t ; c y l i n d e rw a l l
s c u f i n g b e c o m e sa t h i n go f t h e p a s t .W h e ny o u h a v es o m e t h i n gt h a t i s t h e b e s t ,
i m i t a t o r sw i l lf o l l o w .S o b e w a r eo f a n y p r o d u c t h a tc l a i m st o b e a s g o o do r b e t t e r
t h a nP R O - T E CM e t a lT r e a t m e n tI.n s i s to n P R O - T E C .. . T h eB a c e r sP r o v e nL e g a l
Edge
K A R T E RB
SE S TK E P TS E C R E TP. R O . T E CM E T A L T R E A T M E N T
29
l: *.:l*
theflywheel.
Be surethatyouhookthe
fins
the
flywheel
to safeguard
big
on
you
get
your
motor
bro.l-ly thetime
off a fin. Nowtake
kenin andthe greenout of it youhave againstbreaking
hadtimeto mowthe lawn,cleanthe yourstarterratchetsocketandremove
garageandput threecoatsof waxon the starterratchetfromthe crankshaft.
Withyourflywheel
knockersliprt over
yourKart.Zerohour:Nowit's timeto
graspthe
get downto workandturnyourTiller the endof the crankshaft,
flywheel
with
one
handand
back
of
the
intoa RaceMotor.
Engrne
givea sharptapto
hammer
now
with
a
PullthemotoroffyourKartanddrain
knocker.
Never
housing the endof theflywheel
theoiloutof it. Taketheblower
youmayputa
hammer
the
flywheel,
on
off,gastankandthecarb.Nowremove
flywheel
in
whichcouldcause
head.Yuk,whata mess. crack the
the cylinder
it
to
apart
like
blow
a handgrenade.
Witha cleanrag
Carboneverywhere.
gooda time as anyto reNow
rs
as
w i o eo f f t h e l o o s ec a r b o nT. a k et h e
movethecoil.Nextturnthemotorover
headandput it in a panof solvent
to
pistonat the bottomof the
put
soak.DON'TUSEGAST0 CLEANWITH! and the remove
cylrnder
bore,
the valvebody
Youmayburnyourgaragedownwtth
Now
and
the
takeyourthin
side
cover.
youin it. Don'tlaugh,a friendof minein
wall
socket
and
remove
the rod cao.
Calif.burnthis Dad'sgaragedownthis Don'tbendthedipper.
With
the capoff
way.Justluckthathe madeit outhim- push
pistonassembly
rod
the
and
the
self.Nowtakea razorbladeandskim
bore,Now
Af- outof thetopof thecylinder
thecarbonoff thetop of thepiston.
remove
the
cam
and
crankshaft
as a
off thetop
ter youhavethebig chunks
will
The
lifters
fall
into
unit.
the
bottom
of the pistontakesomecarbcleaner
(getin a spraycan at yourlocalAuto of themotor.Butat thistimethatis no
problem.
Nowtakeyourvalvespring
PartsHouse)
anda ragandfinishcleanandremove
compressor
the keepers
ingthetop of the piston.Cleanthetop
Pullthevalveup butrf
from
the
valves.
of theblockandthevalveheadswitha
feelslikeit's hanging,
don'tpullany
ragandthecleaner.
Don'tbe scratching it
more
it.
on
Remove
the
spring
andnow
aroundherewithyou(azor blade.lf
with
file,
file
a
small
off
the
burr
small
youdo,you'reasking
for a D.Q.when
of
where
on
the
end
the
stem
the
keepyougetto theTech.Barn.
er was.Nowthe valvewillslip9p xp
Withthetop of the blockallbackto
andoutof the guide.At thispointyou
Mr.CleanState,set up yourindicator should
havea stripedblock.Nowyou
andgo backthruthestepsof checking havea decision
to make.Lookbackat
piston
pop-up.
Thiscouldhavechanged yournotepad,andseewhatyourpison youas the blockseasoned
in. lf it
w a s .l f i t w a sm o r et h a n
tonpop-up
d i d w r i t et h e n u m b e rds o w nI n y o u r ,002thousandths
in theholeyoumay
notebook.
wantto takeyourblockto a goodkart
N o wt a k ey o u rf l y w h e ehlo l d ear n d shopandhavethemdeckit for youto
hookthetwonotches
into bringthepistonup levelwiththetop of
of theholder
30
. l't-'
,
,
the block,or just a touchoutof the
hole.Wantto knowthe honesttruth
notgoingto seeit ona
aboutit?You're
stopwatchif the pistonis .005inthe
hole,or out of the holeat thistime.
Bottomlineis I advise
thatyoujusttake
yourblockandturnit upsidedownon
yourpieceof glassand600 sandpaper
withcuttingoil on it andsurface
the
faceof theblocktill it'sjustflat.Butto
makeit easierto workon yourmotor
youneedto takeyourcrankshaft
to a
KartShopandhavethempressyour
P.T.O.
bearing
off for you.Don'ttakea
coldchiselanda hammer
andbeatthe
bearingoff.Youwillkillthe bearing
and
mayevendestroythe crankshaft
this
way.Afterthe bearinghasbeenpulled
off youcantakesome180 gritemery
clothanddo a shoeshine
treatment
to
t h e c r a n kt i l l y o u g e t i t j u s ts m a l l
willjustslip
enough
so thatthebearing
onandoff.
N o w ' sa s g o o da t i m e a s a n yt o
turnyourattention
backto thevalve
trainsrdeof themotor.Takea ragand
yourcleaner
andcleanup thecarbon
that is on the valveseats.Wipeout
anyoil or carbonthatmightbeinthe
intakeport of the block.Thecarbon
t h a t i s i n t h e e x h a u spt o r t ,l e a v iet
a l o n eW
. h y ?O n e ,i t m a k e st h ep o r t
smallerwhichit needs,plusthecarb o n b u i l du p m a k e sa p e r f e cht e a t
gassesshieldbearerfor the exhaust
ingthesehightemperatures
fromthe
blockitself.
YourmotorwhenBriggsfittedthe
n i s t o nt h e vs e t i t r r nw i t h. 0 0 5c l e a r
y i v ! v i i t
WORLDKARTING MAGAZINE/DECEMBER 1990
'd
Motorat T.D.C.andreadyto run cam profileon the intake
valve.
Yuk,Whata mess,thlsis theCarbon
vouhaveto cleanup.
INSIDELINE
anceplusor minusa tick.lf youwanta
motortakethe blockto a
toprunning
g o o dK a r tS h o pa n dh a v et h e ml i n e
honetheblockfor youandfit in a new
s t a n d a rpdi s t o nw i t ha c l e a r a n coef
. 0 0 6 5t o . 0 0 7 .B y n o m e a n ss h o u l d
youattempt
thishoning
witha
operation
brush,
brakehone,or 3 jawglaze
bottle
for a car.Leavethisjob to the
braker
you'reat the KartShoppick
Pro.While
valvesprings,
upa newset of valves,
gasket
set,seals,tworodflatwashers,
twolifters,
twocarbjets,filterandfilter
blowercoverscreen,#3 off
adaptor,
setcrankkey,andan aftermarketoil
dipper.
0h yes,a qt. of 4/cycleraceoil.
Pickupyourmessandheadhome.
0n yourwayhomethinkaboutyour
camneedsandheader.
At this ooint
thinkof whatkrndof racingyou'regoing
bigtrackor
to bedoing;
dirtor asphalt,
you're
littletrack,andwhatclasswerght
going
in,Withtheseplans
to beentered
thought
out,thumbthroughthis new
Tech.Manual
andpicka Go-Fast
shop
to orderyourcam andheaderfrom.
placeyourcall
Nowpickup Ma-Bell,
and givethe gentleman
at handthe
aboveinformation.
Withthisdatahewill
be ableto fit youwithyourneeds,
Back
to theshop.
the shopyouhave
Onceback'into
clean-up
to do.lf youthinkyoucanget
by withit andspareyourlife,the wife's
dishwasherwilldo a perfectjob for
you.Allthesmallpartsyoucanfit inthe
knifeandfork bucket.Thebig parts
stackthemin therack.Closethedoor,
set on hot andturnthe machine
on.
Whilethisis goingonandyou're
waiting
for theding,dingsoundof alldone,you
canturnyourselfintoa couchpotato
andcatchsomeT.V.time.lf youthink
that the abovecan be harmfulto life
andlimb,you'llhaveto resortto elbow
grease
andhotsoapywater,
Withall the partscleanedup you
mightjustaswellgo backto thehouse
andput in someT.V.timetill the Brown
Vanarrives
withyourCamandHeader.
T h r e ed a y sh a v ep a s s e dI.n t h i s
lengthof timewhileyouhavebeenwaiting on the UPSmanto brrngyouyour
youhavehadthetime
CamandHeader
theTech.Manuto justaboutmemorize
al. Juston the chancethatyouhave
comeout of a Worldof Big Roundie
goes,you
RoundCarswhereanythrng
mayhavelearnedsomeBADHABITS,
In Karting
we callthisSpiritandIntent,
in the Southit's calledSouthern
Engineering.
Bottomlineis don'tstepover
the line.lf youdo, you'renot goingto
makeit thruthe TechBarnandall of
youreffortshavegoneto waste.MemNeverunderorizethe nextparagraph.
estrmate
theknowledge
of a TechMan;
he hasprobablyseeneverysrdeways
trick in the bookandknowswhatto
lookfor.In short,followthe gurdelines
that I'm settingfor youandyou'renot
goingto get rntoproblems
withTech.
Dontbe grindrng,
rubbing,
or polishing
on anypartof themotor.Makeno decisionson yourown.lf you'renotsureof
something,
Rep.Thisis a
aska W.K.A,
Controlled
and
StockClassof Racing,
,TtFr_f
First.020checkon Camprofile
Frnd
T,D.C.
withpositrve
stopmethod.
WORLDKARTINGMAGAZINE/DECEMBER1990
31
youmustplayby the rulesset down.
Let'sgo to work.
B y n o wy o u s h o u l dh a v ea l l y o u r
partssurgical
cleanandreadyfor asSTAGE
LEFT:
sembly.
EXIIRIGHI,
Firststepthatweneedto do is lapin
our newvalvesso thatwe havea good
lf you
enginesealin thisdepartment.
don'thaveany,it'stimeto makeanother trip to the AutoPartsHouse.You
Comneeda canof Clover3-ALapping
pound,andwhileyou'reat rt,get a can
of J GritWaterSolublealso.J Gritis
verycoarseandyouwilluseit to lapin
the flywheel,
or anyheavycuttingon
thevalveseats.Nowbackto theshop;
takeyournewintakevalveanddab a
lightcoatingof 3-Acompound
on the
valveface,anda touchof oil on the
stem.Dropthe valvein the holeand
withyourlapping
sticklapthevalvein.
Whenlappingthe valve,spinthe valve
backandforthby hand.Hitit about10
or 12 licksthenpullthe valveout and
cleanthefaceof thevalveandtheseat.
Lookrealcloseandseeif the lapring
goesall the wayaround.lf thereis a
showup
highspotontheseatit should
now lf thereis a highspot,therecan
be two reasonswhy.(1) Youdidn'tget
in
valveguidebushing
the replacement
(
2
)
p e r f e c t l ys t r a i g h t , t h e s e a th a s
pounded
downto whereit wantedto be
duringthe run in time.Anothergood
testto tellif theseatis perfectis to put
the valvein the holewitha cleanseat
andvalveface.Nowwiththumbpressureon the headof the valvetry and
turnit. lf the valvefeelslockedin and
won'tturn,the matchis good.lf the
valvespinsthenthereis a highspot
yet.Let'sassume
thatthevalvewillspin
and we feel that thereis not a good
matchbetween
the valveandseatyet.
Layyournewvalveoff to the sideand
takethe old onethat cameout of the
motorandput someof yourJ grit on
the face of this valve,Nowusethis
valveto grindthe seatwith.Thisway
you won'tcut a groovein yourrace
valve.Afteryouhavethe seatcutwitha
goodlap ringall the wayaround
this
waynowtakeyourracevalveandtouch
it off intheseatonemoretimewiththe
3-compound.
Oncedonewiththisvalve,
cleanuo andmoveoverto theexhaust
s i d ea n dd o t h e s a m et h i n gf o r t h a t
side.
the rodandputthe newoneon, Look
insidethe piston,Briggshasput an X
on oneof thewristpinbossesandthe
smallendof therodhasa castedbump
on the sideof it. Putthesetwo spots,
bumpandX sidebyside.Nowtakeand
remove
theringsfromtherunin piston.
Putthe oil ring andthe secondring
f r o mt h i s p i s t o no n t h e n e wp i s t o n .
Makesurethatthe beveledgeof the
secondringrs facingdown.By using
thesetwo runin rings,we cut downon
cylinderdrag,andstillhaveampleoil
controlfor a raceengine.Nowput the
newtop ringthatcamewiththe piston
on the top, lf this ringhasa bevelon
theinsideof it, it goesto thetop or up.
lf thisringhasno bevelon it, it makes
no difference
whichwayit is puton the
piston.Don'tworryaboutthe ring end
gap.lt willhaveenough.
Nowtakeyour
cleaner
andcleanthe boltholesin the
rodout,andwashtherodboltsoff makingsurethatthereis notraceof anyoil
on themor in the holes.Nowyourmotor mayhavecomewitha rodlockon it
(curved
roundpiecewithholesin it)or it
mayhavecomewithjust a flat washer
up on the dipon the boltthattightens
per.0K, if youhavetherodlockonyour
rod,tossthispartintofile 13, andput
one of the #222282flat washerson
eachbolt.lf yourrod boltshadthese
w a s h e r so n t h e mr e p l a c ew i t h n e w
onesanyway.
Nowturnthe rod upside
downandputa goodcoatof oil on the
pinbossesandwristpin.Notso much
that it willrundownintothe boltholes
though!
Nowcoattheoutside
of thepistonwithoil andthecylinder
bore.I use
mollylubefor this so it won'trun all
overthe placeon me.Nowwe'reready
to putthe rodandpistonassembly
into
the motor.RINGPLACING
0N THEPISTON:Noweveryone
hastheiropinion
on whereto put the end gap of the
rings;but sincethis is my Techpiece
we willdo it my way,andl'll tell you
why.Puttheoil ringgapoverthetop of
thewristpinholeon theclutchsideof
the motor.Thesecondring;put this
ringendgap overthe top of the wrist
pinholeontheflywheel
sideof therod,
a n dl a s t p u t t h e t o p r i n ge n d g a p
in linewiththe endgapof the
straight
oilring.Whyhere?
Because
thestart-up
time on a newmotoris the hardest
timeit willeversee,Thepistonrocks
for andaft,andwiththeringsinthispositiontheywillhavelesschanceof the
Nowlet'sputtheshortblocktogeth- endgap diggingintothe softpartof
er.Taketheblockandknockouttheold the alloyof the cylinder.
Oncethe mocranksealandputinthenewone,With tor is started,
theringswillsettledown
thistaskdone,takethe old pistonoff wheretheywantto be intheringlands.
32
Asthemotorruns,theringswillturn
on
the pistonanyway,
andthisis needed
to keepthe carboncleaned
outof the
ringland.Nowslipyourpistonandrod
intoyourringcompressor
assembly
andsnugit down.Nowsettheassern
bly intothe blockandfacethealignmentmarksfor the rodandcaptoward
thesidecoverof theblock.Nowwitha
preswooden
hammer
handle
or thumb
surepushthe pistonintothecylinder
hole.lf for anyreasonyoufeelsolidre
sistance,
stopandmakesurethatyou
don'thavea ringtryingto handonthe
top of the block.Onceintotheblock,
stopwhenthe pistonis levelwiththe
top of theblock.Nowlookintotheside
coversideof the blockandmakesure
that no oil hasworkedits waydown
intothe bolt holesfor the rodcap.lf
youthinktheremightbe oil in them,
cleanthemagainandwipeoutthecase
witha cleanshoprag.
Nextin lineis the crankshaft:
Puta
coatof molloyor oil on theflywheel
seal,thencoatthe bearingor bushing
on that side.Nowyou'rereadyto slide
the crankshaft
intothe motor,Taking
care,workthecrankpastthebottom
of
the rod andintothe block.Once
the
crankis in place,coatthe endof the
rod with molly,takingcarenotto get
anyin the rod bolt holes.Why?
l'lltell
youlater.Nowtakeandpushthepiston
downandseatit on the crankjournal,
Nexttaketherodcapandputa coatof
mollyon it, not lettinganygetnearthe
rod boltholes.Nowput thedipper
up
intoplaceand startthe rod boltswith
yourfingers.Nowtakeyourtorque
wrenchandthinwallsocketandtorque
the rodcapdownto a 100 inchlb.Go
fromsideto side10 inchlbsat a time
till youreachthe 100 inchlb. mark.
Nowthe reasonfor the dry holesand
oil free bolts.Whenyou putoilfree
steelintooil freealuminum
it workslike
lock-titeandthe chancesof yourrod
boltscominglooseonyouis nextto irn
possible.
That'swhywedo it thisway.
At thispointI canseea glintinyour
eyesthat I haveleft something
outon
youbecause
I didn'tgo intoit before
we
got the motortogetherthisfar.You've
heardall the storiesaboutlongrods,
shortrods,longpistons,
shortpistons,
rods,polished
clearanced
cranks
and
etc.Whydidn'tI go intoit withyou?
Simple;this is ENTRY
LEVELRACING
andif
y o u h a v e n 'bt e e nm e s s i n g
around,
W.K.A.
hasgivenyouenough
roomto
be legalandfall withinthe measurementsintheTech.
Manual.
Let'sassume
thatthecamcardyou
in next.First
Let'soutthe camshaft
and
takeyourliftersand slidetheminto gotwiththecamhasbothdegrees
yourvalveandliftersixingblockif you valvelashon it. lf it does,it'sa service
have
one,andtouchoff the endof the thattheCamMakergaveyouas a startlifterson your600 sandpaper
andcut- ingpoint,andkindof handylikea shirt
tingoilto makesurethattheyareflat. pocket.
N o wt a k ey o uc a l i p e ras n dm e a s u r e
Firstlet'sassumethat bothvalves
. hey
e a c hl i f t e rf o r o v e r a llle n g t h T
are
spinning
freelywhichmeansthat
s h o u lbde v e r yc l o s et o 1 , 6 0 0l o n g .
valve
the
is longenoughto touch
stem
your
notebook.Now
Write
thisdownin
puttheliftersintotheirholesandput t h e l i f t e ra n dt h e r ei s n o c l e a r a n c e .
we needto figureout
thecamrntothe motor.Be surethat Now,if possible,
how
much
clearance
thereis between
yougetthecamtimingmarkslinedup
valve
face
the
valveseat.There
and
the
put
witheachother.At thistimedon't
anylubeon theseparts.Beforewe're is a wayto putthisvalvelashfigureto
Let'sassumethat we
donewe willbe in andout of herea our advantage.
intake
are
on
the
valve,andour cam
bunch
of times.Nowputthesidecover
card
calls
for
a
valvelashof .010.
out
onandtorquethe sidecoverdownto
on the headof
50 inchlbs.Nextput the two valves Nowby holdingdown
pressure
valve
with
the
thumb
takethe
intotheirholes.Againleaveoff anyluputting
hand
other
and
start
the
tip of
b r i c a n tN
s .o wt a k ey o u rc l u t c ha, n d
gauge
your
feeler
under
the
head
of
the
put
takethesprocket
drumoff of it and
the {aceandthe seat.
it onthecrankshaft
andslipa keyinto valvebetween
Let'sassumethatthe .005 feelerwill
thekeyway.Byusingyourclutchpack just
slipin andthe ,006is tight.Write
thisway,youhavea handywayto turn
this
downin your notebook.At this
themotorover.Turnthe motorovera
point
we knowthatwe havesomewhere
fewtimesandstopit at TopDeadCenclose
to .015thousandths
of too much
withbothvalvesdown.With
ter(T.D.C.)
you
valve
stem
length.
Now
canmakea
fulllengthliftersandvalvesat thispoint
choice
of
either
it
taking
all off the
mostaftermarketcamswillhavethe
valves
off theseats.Thisis easyto tell valve,or betteryet let'stakesomeoff
lf the valve the lifterandthe valveto get the dethevalves.
byjustspinning
feelslikeit'slockedintoplacelikeit did siredsetting.By doingit this wayyou
w h e ny o us e a t e dt h e v a l v e ,t h i s i s are buyingsomeinsurance
on not lostellingyouthat you havesomevalve ing an expensive
valve.In shorta lifter
c l e a r a n cTeh. i si s c a l l e dv a l v el a s h . c o s t sS 1 . 8 0 ,a n i n t a k ev a l v ec o s t s
Nowbeforewego anyfurther,we need S 5 . 5 0 ,a n d a n e x h a u svt a l v ec o s t s
to talkaboutthe camandthe informa- 57,35.Bottomline;liftersarecheaper
tionthatcamewithit.
thanvalves.Nowlet'smoveoverto the
valve.Afterchecking
withyour
lntheboxwiththecamthereshould exhaust
bea camcardthattellsyouwhatde- feelergaugeyoufindthatyoucangeta
greethecamis to be dialedin at. Most . 0 0 3 t h o u s a n d t hf es e l e ru n d e rt h a t
at ourcamcardwe see
willalsohavecorrespondingvalve.Looking
CamCards
valve
lashonthem.Saywhat,youdidn't thatthisvalvealsocallsoutfor .0i0
geta CamCard.Bettergo lookin the valvelash.Nowwritethisdatadownin
trash,youthrewthe cam cardaway yournotebookandwe will put this into usagelater.Firstwe need
paper.
Whatthat formation
it waspacking
thinking
d r a w i nigs t e l l i n gy o u i s w h e r et h e to makesurethatyourcamwillpass
to Tech.rn yourblock.Let'sset up your
valves
openandshutin relationship
wheel.
is at thatmoment degree
where
thecrankshaft
indegrees.
SomeCamCardswillalso
Sincewe willhavethe camin and
lashof theintake
andthe out of the blocka jilliontimesbefore
have
thevalve
valveon it. MostCamCards we'redone,let'sset the degreewheel
exhaust
won'thavethevalvelashon themand up on the flywheel
sideof the block
t h e r ei s a r e a s o nl '.l lt r y a n de x p l a i n withthe faceof the wheelfacingthe
why.Whenthecamgrindermadeyour motor.Thiswayit willbe setfor theducamhehada certaindegreespotthat rationof theseoperations
comingup,
hewanted
the valveto leavethe seat. andwe canseewhat'sgoingon as we
Healsohada pickeddegreethat he t u r nt h e c r a n k s h atfht r u i t s c y c l e s .
wanted
the valveto go backon the Makeyourpointerout of stiffwireand
valvelashwon'tbethe grrnda sharppornton the endof it.
seat.
Sometimes
insomeblocks,
andhittheneed- Nowclampyourpointer
same
to theblock.A
eddegree
controlled
timewhichis the pairof smallvisegripsdoesa goodjob
V.l.P.
oointof thecam.
here.Nextput yourdegreewheelon
33
the crankwiththe T.D.C.
markings
at
thetop.Thepistonwillalsobe at T.D.C.
andbothvalves
willbe down.Nowtighten the wheelup tightso that it can't
move.Whyso big a degreewheel?
So
we canseethenumbers
at 2:00in the
m o r n i n ga,n dt h e n u m b e r(sd e g r e e s )
aretarenough
apartso wecansplitdegreesif needed.
Nowputyourdialindicatorstandon the blockpulling
it over
so thatit is veryrigid.Nexttakeyour
allendrainplugoutof thebottomof the
motor,runtheoistondownintheholea
waysandputtheplugbetween
thepiston andthe underside
of the indicator
bracket.
Nowwithlightpressure
brlng
the pistonup andthe plugstopped
by
the indicator
stand.Thiswillbe somewherearound40" beforeT.D.C.
Now
turnthe motorbackoverthe otherway
andseewhatyouhavefor a reading
A.T.D.C.
Movethe pointertill youget
t h e s a m er e a d i n go n b o t h s i d e so f
T . D . CT. h i si s w h a t ' sc a l l e dP o s i t i v e
StopMethod
of finding
T.D.C.
Nowthat
we havea perfectT.D.C.
foundandour
valveshavezerolash,we canprofile
ourcam.
Moveyourindicator
standoverthe
top of theintakevalveandputyourindicator into the stand.Turn the
crankshaft
in the direction
thatthe motor runsandstopdeadon the T.D.C.
mark.Nowmovethefaceof the indicator to zero.Seephoto#10. Nowlook
thrutheTechManual
andfindtheTECH
INSPECTION
LISTandthe camprofite.
Foundit?0K, nowturnthe crankshaft
veryslowlytill theindicator
startsto lift.
Nowslowdown,watchthe indicator
comeup to the .020reading
on theindicator.
Don'tgo past.lf youdo,go all
the wayaroundandcomeup on the
.020lift number
again.Nevergo backwards,the free movement
and back
lashwillget youintotrouble.
Nowthat
you'redeadon .020 lift, lookat vour
degreewheel,As youcanseein'the
photothe pointeris pointing
at 16".
Sincethe profilecheckcallsoutfor l8
to 13 degrees
B.T.D.C.
the camis teg a l .l f t h e c a mm a k e sa l l t h e p r o f i l e
readings,
thenyou'relegal.Nowmove
overto the exhaust
valveandrunthe
profileon thatside.lf for anvreason
oneof the checkpointsdon'tmakeit,
go backandcheckeverything.
T.D.C.
(pointer)
mayhavemovedon you,or
youmissedtheT.D.C.
markiusta litile
bit.Afteryouhaveassured
y6urself
that
the problem
is not you,thenI advise
thatyoustopat thispointandcallthe
C a m s h aM
f t e r c h a nt ht a ty o ug o t t h e
c a mf r o ma n dh e w i l la d v i s ev o uo n
whatto dofromhere.
First
A CARBURETOR:
LET'SBUILD
takethe air filteroff andthe throttle
linkage.
Nexttakethethreescrews
that
holdthecarbto thetank,Nowremove
the needleandwitha t/z inchwrench
remove
theneedlenut.Withtheseoff to
Nowwe'regoingto get tricky.With theside,lookintheholeandyouseea
factotpullthesidecoveroff brassjet witha screwdriver
thisknown
notchin it.
of the motor.Nowpullthe cam and R e m o vteh i sj e t . N o wb e l o wt h e j e t
backat thereis whatappears
liftersoutof themotor.Looking
to be another
yournotesyou knowthat yourlifters screwdrive
notch,lT'SNOT:Thisis part
were1.600long.Whatwe wantto do of the carbbody.Don'tputa screwdrivn o wi s s h o r t e nt h e l i f t e r sa n dm a k e er in here.Nowgo to theothersideof
them1.595long.Thelifteris veryhard, the carband removethe diaphragm
so a touchoff on a grindingrockwill cover,diaphragm
andspringcup.Now
help.Nowlapthe endof the liftertill lookintothe frontof the carbandyou
youget a finishof 1.595.Nowputthe seewhatlooksto bea steelblade.This
liftersbackintothe blockandtakethe is calledthe swirl.Witha heavypairof
restoff theendof thevalvestem.lf you pliers,graspthe endof the swirland
to miss,andtaketoo muchoff turningit clockwise
happen
andat the same
a valvestem,youcansavethevalveby timepullingon it, remove
the swirl.Put
goingbackin witha lifterthatis justa the swirlin the roundfile.Nowremove
touchlonger.
the chokelever,andwitha smallscrew
r e a c hi n s i d ea n dr e l e a s e
the
0K, let'sassumethatwe havethe d r i v e r
Pull
the
choke
out
cross
bar
of
shaft.
checks
camalldialedin,andeverything
valve.
These
the
shaft
and
the
choke
0.K,Nowtorquethesidecoverdownto
canalsogo to theroundfile.Nowwith
80 inchlbs.,andchecktheendplayin a long
screwdriverreachdownintothe
thecrankshaft.
Witha dualballbearing carb andremovethe screwthat holds
b l o c ky o u w a n t. 0 0 2 t o . 0 0 5 t h o u - thethrottlevalvein place.(Notehowit's
sandths
endplay.0n an old stylebush- set in hereso youcanget it backright)
ingblockyouwouldliketo have.005to Nowpullthe throttleshaftup andout.
.010 thousandths
of crankend play. At thispointyoushouldhavea panfull
Thisyoucanadjustwithdifferent
thick- of parts,and a carb bodywith two
nesssidecovergaskets
whichyoucan tubeshanging
outof thebottomof it. In
getat yourlocalKartShop.
W,K.A.it is legalfor youto honeor
Withthe end playof the crankset, reamthe venturiof yourcarbto .695
nextremovethe sidecoveronemore maximum.
Morethanlikelyyourcarb
timeandput yournewsealin it. Re- hasthe roomin it to be broughtout
movethe cam and lifters,be careful some.But,thisis not a job for youto
nowanddon'tmixup yourlifters.Next attemptbecause
thereis aboutI in a
withmollylube,oil,greaseor whatever, 1000chance
thatyoucando thisand
lubethecamlifterandcranking
bearing stillmakeit through
theTechBarn.This
good.Don'tforgetto put somelube job needsto be left to a goodKart
intothebushing
holesfor thecamshaft. Shoothatoffersthisservice.Butsince
Nowslipthe bearing
for.theon.(balls we aretalkingaboutENTRY
LEVELRACof thebearing
facingyou,shield
toward lNG,my adviceto you is to leavethis
for a laterdate,
crankshaftthrow)this is a techitem. ooeration
part
you
motor
the
of
Now cansealthis
in yourpanandfind
Nowfisharound
the sidecoverdownto 80
up. Torque
withyourcalipers
the
throttle
shaft
and
inchlbs.
measure
the shaftthickness
andmake
Nowpullthe valvesout one more surethatit fallsin the ,086or big.ger
timeandlubethe stemsgood.Putthe range.lf it doesit's0.K. Nexton your
exhaust
springintoit'splace(longone) listof thingsto do is takea jet drilland
tightcoildownon drillthesmallholeoutto .027andthe
andtheshortspring,
the intakeside.Takeyourvalvespring bigholeoutto .061.Whileyou'reinthe
play drilling
compressor
andputthe squeeze
mood,drrllyourmarnjetsoutto
At .050,.052,and.054.Withthisoperato it andinstallthe lowerretainers.
withour tion-done,
thispointwe arealsothrough
yourdiaphragm
surface
covdegree
wheelsetup so youcannowre- er on your600 sandpaper
andget it
movetheseitems.Putthe valvebody flat.NowyouhaveanAlkyburning
carcoverbackon andsetthe completed buretor.
Cleanallthe partsup andput
shortblockoff to the sideandcoverit
upwitha cleanshoprag.Wehaveother
workto do.
34
A s w e g o b a c ka n d l o o ka t o u r
notes,we findthatit sayswe havea total of .0i5 too muchvalvestemlength
on the intakevalveand,0i3 too much
valve.
valvestemlengthontheexhaust
the throttleshaftbackin first.Withthe
shaftin andthe throttlevalvebackin,
bendor filethethrottlestopsothatthe
throttlevalveis straightwiththe carb
b o r e .P l u gu p t h e h o l e sw h e r et h e
chokepartscomeout andthe bottom
holewheretheaircleaner
boltwas.Put
your.052mainjet inandsettheneedle
1'/z turnsout. lf we haverunoutof
parts,guesswe'realldonewiththisop
eration.
Setyourcarboff to thesidefor
n0w.
you
By lookingat the TechManual
can seethatthe headcanbe cutto
spec.At this pointyoucantakethe
headto the KartShopandhavethem
do it for you,or youcando it thehard
wayonyourpieceof glassandsandpaper.lf youdo the headyourself
becare
fulthatyoudon'tgo pastthelegallimits
it
set down.Withthe headdone,clean
up andtorqueit downto a 140inch
lbs. I put a touchof oil on myhead
bolts.Thesearebestnotputindry.
Nowturnyourshortblockaround
it upto
andputthecoilbackon.Raise
the top of the holesand snugit into
place.Nextput yourflywheel
on and
slipin your#3 key.(offsetto theright)
andtorquethe starterratchetdownto
75 ft. lbs. Leavethe screenoff the
back
starterratchet,butputthescrews
intotheirholes.lf youdon't,thesideof
theratchetwillcomeoff andthestarter
ballswillfall out. Nextturnthemotor
is
overtill the alloypartof theflywheel
underthe coil legs,Nowput a .0i5
feelergaugeunderthecoillegsandr+
leasethe tensionon the coil boltsletWith
tingthe coildownon theflywheel.
the coilboltstightyouwant.015air
gap.lf youhaven't
already
doneit, re
fromtheblower
movethestarterrewind
coverand put yournewblowercover
screenon. Putsomelocktiteonthese
bolts.
It'sdownhillfromhere,putyourcarb
on nextandthe tank.Makesurethere
is no bindin them.NowputyourHead
er. FilterandBlowerCoveron. Setthe
s p a r kp l u gg q pa t . 0 2 5t o . 0 2 8a n d
tightendown.lf youfeel fast youmay
wantto get a colderplugfor yournew
Putthe drainplugsbackinto
engine.
themotorand16 oz.of oilfora filluo.
Bolt your RACEM0T0RT0 YOUR
KART
andlet'sgo RACING.
Tech,Ed.
E.C.
greewheelthatwillmountsolidand
withno runoutis a must.Forsurethis
I Ht RACE
lS NOTovertill you have is oneplacewherebrggeris an edge.
wonthefourthheat,thirdoneif it starts Whyfor thebiggerwheel?
Because
the
to rain;butwiththelevelof competition linesarefartherapartper degreeand
thatyoufindin the Worldof WK.A.Four thismakesyouraccuracy
better.Same
Racing,
arewalking
Cycle
theWinners
a
waywitha dialindicator.
Thebiggerthe
verytighiline.
dialfacethecloseryoucansplithairs.
wentwith
Lastyear(1989)W.K.A.
T h e r e 'a
s c o u p l eo f w a y st o f i n d
c a m sa s b e i n ga l e g a l T.D.C.
h a n dg r o u n d
waysare
andthemostcommon
camfor BoxStockand SuoerStock setyourwheelupusingyourdialindicaclasses
as longas theyfell intothe tor going.100 pistontravelon both
andguidelinesof theTech
camprofile
Manual.
Inshortthosethathada onein
handoickedcamsthatno
a thousand
money
couldbuyhadtheiredgedulled.
Likeanytypeof blueprinting,
theacof yourworkis a directrelation
curacy
to thequality
of thetoolsthatyouuse.
ForthefirstpartI feelthata largede-
?.EWMoroRs
-{f
Ail
sidesof T.D.C.
that'soneway.Second
wayis to usea positive
stopmethod.
Thiswillassureyouno mistakes
and
thewayI do it. lf youlookrealcloseat
photo#1 youseethatthedegree
wheel
andthe indicatorare bothon .000.
Lookrealcloseat the indicator
stand,
it'sboltedsolidto the blocksettingon
topof a 1.000brassblockwitha notch
machined
intothe bottomof it. Now
wrlha I/2 inchsocketsetontop of the
pistonthetravelof thecrankis stopped
w h e nt h e s o c k e h
t i t st h e t o p o f t h e
notchat 23'. Whenthe wheelshows
is lockedin.
thison bothsidesT.D.C.
Oneotherpointworthpointing
out is
lookrealcloseat thepointer
for thedegreewheel.
Whenyou'reblueprinting
a
Th-eWinningestDecision
Y o u - i lE v e rM a k e .
Box Stock 4/Gycles
and
OR
Modilied. 2/Gycles
Sets The Pace For All to Follow.
qlg?',+'i,T
.- JlrtED
Finding
absolute
topdeadcenterrsa
rnust.
Box Stock 4/Cycles
and
OR
M o d i ife d . 2 / C y c l e s
Hereyou can see at the lst .020
checkat max18" thecamls .0038
to fat.
WORLDKARTING MAGAZINE/NOVEMBER 1989
duration
out of yourcamyouhaveto
havethecamlobefatter(bigger)
asthe
lrftercomesup off thebasecircleand
ontothecamlobe.Camgrinders
know
thisandpushthisduration
factorto the
l i m i ti n s o m es p o t sa, n dw h e nd o i n g
*
this
thereis always
thechance
it might
#
bea touchto fat somewhere
intheorofilecheck.Nowif youwanta camwith
a lot of meaton it so youcantailor
makeit the wayyouwantget a LK.F.
cam.l.K.F.
have
doesn't
the.020check
andDynoandCobra
Camsmakea cam
likethis.In shorttheirfat at the .020
checksandwon'tmakeW.K.A.
Tec.
A f u l ld u r a t i oW
n . K . Ac.a mw i l lb e
pushing
thecamTecto themaxonthe
frontsideof theintakelobeandsomet i m e st h e b a c ks i d eo f t h e e x h a u s t
lobe.Bybeingbiggerherethevalvewill
be openfartherat a lowerdegree
readingonthewheel.In shortmaxduration
is builtintothecam.Forthemostoart
if the camis too fat, it willbe on the
Howto builda "Peek"A-Booblock
.020liftnumber
in thecamorofileusufor degreewheel
andnotemounting
Valve
springinstalled
andfileplaced
pointer.
allyon the intakesideof thecam,and
under|ifteroncamreadyfor filing.
goingout on the backsideof the exhaust.
t h e d e g r e ew h e ew
l o u l ds h o w2 1 . 5 "
BOX STOCKCAMS
To get yourcamto comeintoTec andyouwouldbe on yourwayoutof
thereis a coupleof waysto do it. First theTecBarnwiththe4thHeatLostand
camyourin andoutof theblocka mil- lookat the photoof thetoolsneeded. a BigD.Q.beside
yourname.
liontimesandyoucan'thaveanything As youcanseein thephotothereis a
move0nyou.lf it doesyourinfor more s m a lhl a m m e Ir /, 4 i n c hd u p l i c a t i n g Stageright,Exitleft.Nowwe know
w o r ka n dp r o b l e m sT.h i sp o i n t eirs
punch,anda number
2 finefile.(yes thatthiscamis to fat, andwe haveto
m a d eo u to f I / 8 i n c hs t a i n l e ssst e e l that'sa longpickuptubeoff a Stock get it backintoTecwithouthurting
CamGrinder
designed
intoit.
w e l d i nw
g i r e .l t r s w e l d e dt o g e t h e r Carbfor a filehandle).
Thelowerretain- whatthephoto
you
Look
#3
at
and
can
see
that
forminga triangleandthe two lower ershavethefrontsidecut outof them
my
Cam
Test
Block
has
holes
that
have
c o r n e ra
s r eb o l t e ds o l i dt o t h e c o i l andthewelded
on handles
makethem
intothesidesandfront
mounts
of theblock.Thisrsa verystrff easyto slipin andoutfromunderthe beenmachined
"Peek"
This
of
it.
A-Booblockleaksa
r l d g e ds e t u p a n do n c es e t w r l ln o t valvesprings.
Youcan'tseeit in the
little
oil
come
race
time;but it runs
moveon me. lt takesa littletimeto
photo,butonesideof thefilehashad
Needless
cool.
to
if youdon'thave
say
makethe toolrng
thrsway;but in the theteethground
offandpolished
flat.
a n o l d b l o c kw i t hg o o dc a mb o s s e s
longrunit paysoff.
Nowlookat the photoandyoucan andect. in it youcan'ttakeyourRace
As a general
ruleof thumbtheway seethatwhenthedegree
wheelis set- Motorandcutholesintoit justto make
yougo fasterrs put moreair fuelmix- t i n go n i 8 " ( f i r s tc h e c kp o i n to f t h e a
testblock.Buta testblocklikethisis
tureintothemotor.Afterthesparkplug camprofile)
the dialindicator
is show- theeasywayto Blueprint
a Cam.
hasdoneit'sthingthecamopensthe ing.0238.In shortit'salmost.004to
just
you
let's
0k,
havea good
say
exhaust
valveandgetsthe burntmix- fat at thischeckpointto makeTec.lf
block,
or
take
a
new
one
likeI didand
tureoutof themotor.Nowto set more youwasto stopthe valveat .020 lift
makeyoua "Peek"A-Booblockfor a
CamTestBed.Lookbackat Photo
#2
andyoucanseethecamhasliftedthe
valve.0238.Inshortwe haveto getrid
of .0038liftto makeTec.So lockthe
crankup withthedegreewheelon 18"
( l u s e2 / c y c l eb e a r i n g
s h i m so n t h e
P . T . 0s. i d e ,u n d e rt h e b e a r i ntgo d o
this)Nowwitha intakespringon the
valveslipyourretainer
toolintoplace.
Nowlift up the lifterandslideyour
file(smooth
sidetowardlifter)between
lifterandcam.(photo
#4)Double
check
yourdegree
wheeland makesurethat
36
WORLDKARTING MAGAZINE/NOVEMBER 1989
,1:.:;1
:,:,,;,,,
:1i,:;i.;!;,li],jl!:;,;;:iiilitl,;
ry@ry@g
Handtoolsneededfor Camshaft
Blueprinting.
BOXSTOCKCAMS
youarestilllocked
inon i8.. Nowoush
andpullyourfilein andouta fewtimes
letting
thepressure
of thelifterholdthe
fileflatandtighton the cam.Thisway
yourfileis cuttingthe camjust at th6
spotwherethe lifterwill set at cam
Tec.Afteryouhavemadea fewstrokes
pullyourfile out andwipeoff the cuttings.Tobe on the safesidecheck
yourT.D.C.
andmakesureit'sstillright,
nowun-hook
thespringandcheckybur
18"checkpoint.Keepfilingandch-eckingtillyouget a matchup of .020 lift
andl8'on yourdegree
wheel.
lf youthinkit's
off, try putting
lurdtg getthematerial
it backon afteryouhavegonetoo fal
tnsnort,takeyourtime.Romewasn't
builtin a Dayandtivingthe lifeof the
taster
lanehasneverbeeneasy.lt's a
hardtaskBlueprinting
a Camth-iswav:
but.the
rewards
arepaidto thosethit
g0tastest
andmakeit through
theTec
Barn.
37
WORLD KARIING MAGAZINE/NOVEMBER 1g8g
o n i t t h a t y o u w o n ' t u s e f o r r a c i n gb u t w i l l w o r k a s a s p a r ef o r
M o m s l a w n m o w e rt h a t d o e s n ' tg e t u s e d m u c h b y y o u . T h e
m o t o r i s s t i l lw r a p p e du p i n a F a s tB l a c kC o l o r .T h i s e n g i n ei s
a l s oa n a l l o yb o r ef a t b l o c kw i t h t h e n e w c r a n ka n d s i d ec o v e r .
L a s to n t h e l i s t i s t h e l . C .S e r i e sb l o c k w i t h a c a s t e di n s t e e l
c y l i n d e rw a l l .T h i s i s t h e W o r k H o r s ee n g i n eo f B r i g g s& S t r a t l pplications
t o n a n d u s e do n r e n t a le q u i p m e n ta n d i n d u s t r i a a
w h e r ed e p e n d a b i l i t a
y n d l o n g e rc y l i n d e rl i f e i s a m u s tw i t h o u t
. h i se n g i n e
d o w n - t i m ef o r p i s t o n ,r i n g sa n d c y l i n d e rs e r v i c e T
i s a C h a r r nY e l l o wi n c o l o r a n d t h e M o d e l N u m b e ri s 1 3 3 2 3 2 0090-01.As a racerwhat is the down side of this motor?None
o t h e r t h a n y o u h a v e t o r e p l a c et h e t a n k a n d t h e c a r b u r e t o r
w i t h t h e o n e t h a t i s l e g a lf o r K a r t r a c i n g .W i t h t h i s m o t o ry o u
a l s o h a v ea n o t h e rs p a r em u l f l e rf o r t h e l a w n m o w e ra n d a n u t
and bolt bucket.You will also have to pull the piston out and
put in differentringsto be legal.(Sameonesthat you usein the
a l l o yt y p e c y l i n d e r s . )
Now let's take a quick look at the NEW Briggs & Stratton
Motor Sports Division Spec Engine. lf everything goes as
p l a n n e d ,w e s h o u l d s e e t h i s m o t o r i n t h e k a r t s h o p s b y m i d
beforethe next racingseasongets in a W.F.O.condition.
&8Ng-
TROM STOCK TO
SUPER STOCK
Story and Photosby E.C. Birt
Sorrywe missed2 monthsbut I had Daytonaon my hands
and missedthe deadline.Now everythingis in a controlled
slideand we will get backon the track.
Whata seasonwe havehad in kartingand the newone in
bloomis goingto be betteryet.
By now all of you haveyou newTech Manualfor the 1993
seasonand if you look at the new rulesfor the SuperStock
Classit hasto get your attention.The four cyclecommittee
hasworkedovertimeto makethisa superclassfor the karter
thatwantsto moveup to a fasterridewithouttheexpenseof a
Limitedor Openandat thesametimekeepthecostaffordable.
On the new sideof things,Briggsand Stratton,the backboneof karting,hasbeenmovingW.F.O.
forthelastyear.The
newDivisionol BriggsMotorsSportsis takingshapeandbig
thingsarecomingthatwill benetitall karters.
BriggsandStrattonEngineshavehadsomemajorchanges
thisseasonand they haveall beento the positiveside.In the
Engineline-upwe havetwo (2)newengines.
ThenewBriggs
SpecEnginethatwason thedrawingboardlastyeariscloseto
completion.
Moreon this laterand someof the insightson
whatto lookfor.
At the moment let's look at the new motors and part
numbersthat you can use for karting.Then we will hit the
motor changesand get a sneakpreviewof the new Spec
Engineandmoretrixthatareplanneddowntheroadby Briggs
& Stratton.
Motor#1: Thisengineis builtoutof AlloyFatBlockthatwas
introducedlastyearwiththef ly wheelsideof theenginebeing
alloybushingfor the crankto run in
of the moredependable
witha ballbearingP.T.O.sidecover.Thebig majorchangein
this motoris the crankshaftand the P.T.O.cover.This new
1-01
intothe130232-511
crankandsidecoverwillinterchange
. Thisis
or olderones.ModelNumber135232-1012-01
engines
what Briggsand Strattonsellsas an O.E.M.enginefor the
Thisengine
kartingmanufacturers
and otherspecialusages.
on it thatwe usefor racing.lt
stillhasthe#397135
Carburetor
alsocomeswitha f ilterthatyouwon'tuseonyourracerbutthe
liltertopmakesa goodnutandboltbucket.lt alsohasa muffler
APRIL1993I KARTERNEWS
38
ln the Briggs& Strattonline-upof motors,the l.C. Steel
enginebuilt.Bottom
eevedEngineis the mostdependable
line to this is that it will take abuseraceafter racewithout
dying on you. The long sideof this statementis that witha
steelsleevedenginethe cylingerwall won't gall as easyor
wearas quicklyas the alloytypeof cylinderwall.
Witha SuperStockor a LimitedModiliedif you geta heavy
amountof Alky into the motoryou washthe cylinderwall
you havea scoredcylinderin
down.Whenlubricationleaves,
thealloyblockin a heartbeat.
Withsteelsleevecylinder,if this
washdownproblemhappensto you yourchancesof damage
is cut by 750/0.
A lookon the othersideof the coin.lf you arenewto the
sportor if youfall intothesamegroupasothersandyoudon't
havethetimeor the knowledge
to pulla majorteardownand
serviceeveryweekor two, thenthis is the typeof blockthat
you need.
Theproblemthatyou'refacingnowthoughis thatto getan
l.C. SteelSleevedEngineyou haveto buy a RentalEngine.
and tankarewrongplusthe pistonringsthat
The carburetor
comeon the pistonaren'tlegalto use.Soyou haveto replace
andpistonrings.Thisis anolherexpense
thetank,carburetor
put on the kartermakingthisa veryexpensive
conversalion.
Theanswerto all of theaboveproblemsisto builda motorto
thefollowingspecs.
The blockfor this enginewill be the l.C. SteelSleeved
Cylinder.In all the LC. SeriesMotorsthe spaceage D.U.
bearingcomesin the flywheelside of the block.This O.U.
bearinghaslessfrictionand crankseizureproblemshereis
cut in halfif youletthemotorgetlowon oil.Thepistonwillbe
of thealloytypewithno chromeon it.Thiswillcutdownonthe
chancesof the chromecominglooseor flakingwhichcan
causecylinderdamage.
Theringswillbeputon thepistonthat
are LK.F.andW.K.A.legal.The valveswill be the sameones
thatareusedin theAlloySeriesof engines.Of coursethelegal
gastankandthe#397135
thatis legalwill beused.
Carburetor
Anotherneededitem that a raceengineneedsis thatthe
valveguidesneedto be brassand on both valves.So to cut
morecostto the racerthe long BriggsValveGuideBushings
(#231349)
will be put in the blockfor the exhaustand intake
valvesto run in.Thiswill solvea majorproblemfor thekarter.
Withthesenewguidesputin theblockyouwillbeableto take
a simplepullerandremovethemwhenyougetguidewearand
pop in newones.
Theblock,sidecoverandheadwill beunpainted
butcoated
with a new trick clearcoat that will cut down on corrosion
problems.
Fortheoutsidewrapping,theblowercoverandthe
restof thetin will bea verystand-outracingcolorto giveit it's
own identity.
So there you havea sneakpreviewof all new Briggs&
StrattonRaceengines.The betterthings in lile are always
w o r t hw a i t i n fgo r a n dn o wi s t h e t i m e f o r aenn g i n e ot fh i s t y p e
for the racersandtheentrylevelracerthatis newto thesport
of karting.
Thecoloror thegraphics
for the blowercoverandtin have
I
I
:l
yetforthisnewracemotor.Bottomline:get
notbeenfinalized
padandcoloredpencils
outyour
sketch
anddoyourthingand
sendmeyourideas.I couldusesomehelpin thisdepartment
ol thelayout.I likeCompetition
Orangefor the color.Havea
betteridealetmeknow.
Withthenewcrank,the PTOend of the crankis stillat 3/4
inchbutthebearingpartof the crankis at 1.000.Thismakes
lhecrankgeara bit on the thin sidefor the cam.But haveno
lear,Horstman
has alreadytakencare of this problemand
made
a crankcamgearfor here.At thispointin time,thisgear
isnotlegalto usein SuperStockor StockClassesbut,il there
thatshowup in thefieldandfailureof the
areanyproblems
stockgearI'msurethatthe4/CycleTechCommittee
willmake
thisgearlegalto use.
wegetintothe Superstockclassset-uplet'slookat
Before
the new crank and PTO cover of the Briggs & Stratton
Engines.
Thefirstthingthatcatchesyour eyewhenyou seeone of
thesemotorssettingon the benchis the slimmerlook and
different
blowercover.Whenyou moveto theothersideof the
younoticea biggerO.D.on thecrankshaft
engine
comingout
of thecover.
Backtotheblowercoverside
of themotor.Theslimmerlook
isdueto thechangeof the all newrewindstarterandthefact
thatthecrankshaft
hasbeencut off.Thenewinnerwindpart
ofthestarteris justheldon with a nut andsincethe old pilot
partol thecrankfor starterrachetwasno longerneeded,the
got the shorttreatment.
crankshalt
Nowall you racersthat havebeenlookingfor the old light
weightstarterrachetsthat haven'tbeenmadefor 25 yearsor
so canquit lookingfor them.The only problemwith this
rewindstarteris that you haveto leaveit all on the blower
coverto startthe engine.
Mostof thelocallrackswherethesenewmotorsareshowing up are letting the karterstake the rewind olf and use
olectric
to startthemotorwith.lf youthinkaboutit it is
starters
asafety
movefor all.lt'snotgoodfor youto haveto behuffing
onthegastankto getfuelup in a BoxStockersoyoucangetit
tostartandsometimes
witha SuperStockerit canbe a close
raceon gettingtheengineto fire;anda cardiacarrest.
Withtheweightremovalof thestarterrachetf romthecrank
I'msuretherewill be morepowerthat will go to turningover
lherearwheelsof yourkart.Not enoughthatyou'regoingto
oeeit on thestopwatch,I don'tthink but,any rotatingmass
removed
fromthe crankhasto help.
Withthenewblowercovertherehasalsobeena changein
thecylinger
headcasting.Thenewsquarestyleblowercover
hasa boltholeon eachsideof it to bottthe coverto the head.
Thiswill be a big helpon Superstocks,Limiteds,Modifieds
andetc.on shakingthe bolts out of the blowercoverand
havingit lall off in the race.
The O.D.of the
Backto the othersideol the crankshaft.
crankcomingoutof theP.T.O.coveris 1.000witha new1.000
LD.bearing
ontheinside.Thegoodsideof thisisthatthereis
a biggerflatspotherethatwill helpkeepclutchesf romclimbinguponthecrankshoulderespecially
the 11toothclutches.
EXITRIGHT!STAGELEFT!
SuperStockClassandyou.
I'mnotsure,sincetimegoesby sofast,but I thinkit was5 or
sixyears
agothatl.K.F.setuptheSuperStockClass.Thiswas
oneof thebetterideassincepopcorncandybecausewhatit
didwasmakea stepping
blockf romtheBoxStockClassto the
Limited
ModiliedClass.
TheLimitedModifiedClassisjusttoolastof a classfor a Jr.
driverto be in and that'sthe way it usedto be. A Limited
Modified
is alsotoo fast for most Sr. driversthat are iust
comingout of the Box StockClasses.The cost to build a
Limited
isalsomorethana SuperStockandsayit like it is,a
Limited
breaksmoreoften.
WhentheSuperStocklirstcamein it took off likea rocket
thenstarted
a downhilltripto thedeathmarch.Thiswasdueto
39
t h e d e p e n d a b i l i toy f t h e e n g i n e sT
. h e m o m e n ty o u p u l lt h e b o x
s t o c k c a r b o f f a n d p l u g a T i l l o t s o nc a r b u r e t o ro n t h e e n g i n e
you have close to a 30o/oincrease in horsepower and the
e n g i n ew i l l n o w r e vt o 7 , 0 0 0R . P . M . ' sB. r i g g s& S t r a t t o nd i d n ' t
designthe piston and rod in their motorsto take this 300/o
i n c r e a s ei n p o w e ra n d R . P . M . ' s .
In short, rodsstartedto break;wrist pin bosseswereyanked
o u t o f p i s t o n sa n d B a y W i n d o w B l o c k sw e r e t h e o r d e r o f t h e
day. What started out being a good idea turned into a Heart
A t t a c kl o o k i n gf o r s o m ep l a c et o h a p p e n T
. h e b o t t o ml i n ew a s
that few racerscould alford the cost of this breakageand zero
dependabilityso the classstructure just about died becauseof
these problems.
Last year before the 1992 season got started,W.K.A. got
with the people from Wiseco Piston and Horstman Manufact u r i n ga n d g a v et h e m t h e g r e e nl i g h t t o m a k ep i s t o n sa n d r o d s
for the Briggs engineswith the same spec as that of the stock
parts but out of materialthat would hold up to the horsepower
of the Super Stock Class.
The SuperStock Classis now seeingan up-swingin growth.
The overallacceptanceof the class hasskyrocketed.The cost
of buildinga good SuperStock is %the cost of buildinga good
Limited and it is very close to being just as fast a ride. A good
Super Stock takes half the time to maintainas a Limitedand a
quarterof the time to maintainas a good Stocker.
With the high tech of todays' Limitedsthese Stateof the Art
engineshavebecomevery costlyto build and they break more
often. Which is another big cost to the racer.
What is the bottom line to all of this? Well for sure nothing
will ever take the place of Box Stock racing becauseof the
competitivelevelof racingthat it is. But mark my word, by next
season the Super Stock Class will be one of the biggest
classesgoing nationallyand on the Home Front.
Okay let'sassumethat I now haveyour interestlevelup. You
havedecidedthat you havebroken enought Box Stock Carbs
and you're tired of working an averageof 24 hours a week in
the shop on your stockerto keep it competitiveand would like
to put in some more TV time.
T o t o p i t o f f y o u j u s t b r o k ea n o t h e ro i l d i p p e r l a s tt i m e o u t .
You got lucky that the rod didn't weld itself to the crank and
hand grenadethe motor. But after miking the crankshaftyou
know there is enough wear on it that you will haveto replaceit
with a new one or it will break again next week.
While you're there you know you better replacethe piston
and rings becausethey both havethree (3) raceson them and
the engineseal is not as good as neededf or a race motor. Plus
maybe it would be more fun to go a little faster and you just
noticedthat you have another cracked carburetor.
To makeyour move into the SuperStock Classyou'regoing
to haveto do a little shopping.The best advice I can give you
here is buy right the f irst time and you won't haveto do it over.
So let'smake us up a shoppinglist and then we will cover what
to do with the piecesas we put the motor back together.
The partsthat we will needare as follows: piston, rings,rod,
Tillotsoncarburetor,filter adaptor,filter, intakemanifold,fuel
p 0 m p ,f u e l f i l t e r ,l i n k a g ek i t a n d a f u e l t a n k .
From here on out t'm going to be bouncing back and froth
f r o m N E W E n g i n et o u s e d e n g i n e a n d f r o m f i r s t t i m e E n t r y
Karter to the Pro. So when I come to a spot that you Pro's
alreadyknow, I'll give you warning and you can go raid the
f ridge.
L e t ' sl o o k a t t h e e n g i n e sf i r s t .W e w i l l a s s u m et h a t t h e m o t o r
i s l i k et h e o n e t h a t w e t a l k e da b o u ti n t h e b e g i n n i n ga n d a u s e d
race motor that has been seeing action as a Box Stock Race
Motor.
For those of you that are rat Entry Levelwe will assumethat
y o u h a v ej u s t b o u g h t a b r a n d n e w m o t o r a n e w o r u s e d k a r t
and this is the very first time you haveever picked up an issue
o f l . K . F . ' sK a r t e rN e w s .
The bottom line:you're as lresh as morningdew. Okay Pro's
i t ' st i m e f o r y o u t o g o r a i d t h e f r i d g e .
KARTERNEWS/ APRIL 1993
a r t i c l eb y i t s e l fw h i c h i s p l a n n e dl o r t h e n e a rf u t u r e .B u t i f y o u
haveone of these2/Cyclegas carbs and want to use it giveme
a c a l la n d l ' l l h e l py o u m a k ei t u s a b l e .
Intakemanifoldsare anotherchoice that you haveto make.
For the most part a 1.500to 2.000inch center line is the best
place to start.
F i l t e r sW
l h a t c a nI s a y .I l i k e S & B o r K & N . T h e o n l y o n e s
that I will use.
F o r a f u e l f i l t e ry o u c a n ' tb e a tt h e W a l b r oI n - L i n eF u e lF i l t e r .
Fuel pumps. Now here I'm going to get some conversation
but there are f uel pumps that weren'tdesignedto work olf the
intake pulse for the pump. The way the Tech is for the Super
S t o c kC l a s s ,L i m i t e dM o d i fi e d a n d M o d i fi e d B r i g g s ' C l a s st h, e
fuel pump pulse has to be taken from the intakemanifold.For
this type of pump to work right there has to be a pressure
r e l e a s ef r o m t h e s u r g e d i a p h r a g mt o t h e a t m o s p h e r ei n t h e
p u m p .T h e e a s yw a y t o t e l l i f t h e p u m p i s o f t h i s t y p e i s t h e r e
w i l l b e a h o l ed r i l l e di n t h e t o p p l a t eo f t h e p u m p o r t h e r ew i l l b e
what looks like a brass rock which is a filter on the top of the
pump.
W h a t h a p p e n si f y o u h a v et h e w r o n g p u m p o n y o u r m o t o r ?
For the most part you will havea flat spot off the turn or a bog
off the start line break.This is a problemthat a lot of kartshops
don't know about and for the most part the carburetorgets
blamedf or somethingit has no control over.In short,if thereis
n o f u e l f o r t h e c a r b u r e t o ri t w i l l g o l e a na n d y o u w i l l h a v ea l l a t
spot when you step on the throttle. (Look at the picturesand
y o u w i l l s e e w h a t l ' m t a l k i n ga b o u t . )
N o w b a c kh o m ew i t h y o u r b o x o f g o o d i e sy o u ' r er e a d yt o g o
to work.
Firststep:you need to wash all the parts block and etc.spic
and span. lf mom has gone to town and you feel lucky,her
d i s h w a s h ew
r i l l d o a d y n a m i t ej o b o f c l e a n i n g .B u t t h i sc o u l d
turn out to be more hazardous to your health than using
gasoline to wash the part in. Better just use hot water and
soap. That's the safe way. lf the motor is new I would advise
that you trade the new crank in at the kart shop for a hardened
c r a n k . l f y o u r u s e d c r a n k h a s a l i t t l e w e a r o n i t ( . 0 0 2o u t o l
round) and at the point where it breaksdippersyou can probably get by with it. The race rods with the insertsin themcan
take a lot of punishment.
F r o m h e r e o n o u t I ' m g o i n g t o b e t e l l i n g y o u s o m et h i n g s
t h a t y o u c a n d o t o m a k et h e S u p e rS t o c k e n g i n eb e t t e rT
. hey
are on the list of things for the 4/Cycle Board to discussbut
may not be legal to do this year.
Lastyear when Briggs & Strattonwent back to the alloytype
o f b u s h i n g o n t h e f l y w h e e ls i d e o f t h e m o t o r I k n e w t h e r e
w o u l d b e s o m e p r o b l e m ss h o w i n gu p i n s e i z e dc r a n k si n t h i s
b u s h i n gS
. o m ed u e t o t h eo i l b u i l d e r sb e c a u s es k i n n yl i g h to i l i s
the fastest way and they were caught off guard. Now for the
m o s tp a r tt h e y h a v ea l l c h a n g e dt h e i rf o r m u l a st o c o m p e n s a t e
f o r t h i s . T h e r e w e r e o t h e r o i l a d d i t i v e st h a t c a m e o u t t o h e l p
with this bearingload.
Here you have to be careful because some of theseoil
additivesthat help the crank seizing problemsalso set off the
o i l b e e p e ra n d y o u f i n d y o u r s e l fw i t h a D Q p r o b l e mo n y o u r
h a n d s .S o m e r a c e r sl o u n d o u t t h e h a r d w a y t h a t t h e y h a dt o
p u t i n m o r eo i l l h a n w i t h t h e d u a l b e a r i n gb l o c k s .S u r e ,n o o i l ,
o r v e r y l i t t l e i s f a s t f o r a w h i l e b u t y o u h a v et o f i n i s ht h e r a c e
before you can win. Last on the list here is the racerthat put
s o m e m o r e o i l i n t h e m o t o r a n d w e n t t o a b e t t e r g r a d eo f
. h i s w a sm o r e
l u b r i c a n tb u t s t i l l h a d c r a n k s e i z u r ep r o b l e m s T
t h a n l i k e l yd u e t o t h e t a c t t h a t t h e b l o c k o n t h i s s i d e i s t i g h tf i t
a n d h a s t o b e b r o k e ni n .
W h a ti s t h e b o t t o ml i n ef o r t h i s p r o b l e m ?W e l ln o n ef o r n oo i l
o r v e r y l i t t l e .B u t a s i m p l em o d i f i c a t i o nt o t h e b l o c k t h a ta n y
k a r t e rc a n d o w i l l c u t o u t 9 8 0 /oof t h e p r o b l e mi s t o d r i l la 7 ai n c h
oil feederholein the block for the crankshaft.The only problem
h e r ei s t h a t a l o t o f r a c e r sd o n ' t u n d e r s t a n do r k n o w h o wt o d o
t h i s m o d i fi c a t i o n T
. h i s i s o n e o f t h e i t e m st h a t i s o n t h e4 / C y c l e
T e c h C o m m i t t e e sl i s t f o r p a r l a yt o b e a l e g a lm o d i f i c a t i o n .
A f e w s i m p l e h a n d t o o l s a r e n e e d e d :% r a c h e t , t o r q u e
wrench, l/qlhrul/zinch sockets,a 4.000extension,breakerbar,
c o m b o s c r e w d r i v e rs e t a n d i f y o u j u s t b o u g h t a n e w s h o r t
c r a n k m o t o r a 1 5 / 1 6s o c k e t t o g e t t h e c r a n k n u t o f f . W h i l e
you're buying socketsyou need to gel a 5/16-12point for the
rod bolts. You can get the tools you needf rom Searsor SnapOn. Wal-Martor K-Mart tools will get you by.
At your local kart shop or lawnmower dealer you need to
p i c k u p s o m e B r i g g s & S t r a t t o ns p e c i a lt o o l s . ( 1 ) F l y w h e e l
holder #19167;(2) Valve Spring Compressor#19063or trick
v a l v es p r i n gs p o o n ( t h e r ei s n o p a r t n u m b e rf o r t h i s o n e .L o o k
at the picture and ask for it.) (3) Piston Ring Compressor
# 1 9 0 7 0 .F o r a t o r g u e w r e n c h y o u w a n t t o g e t t h e b e a mt y p e
t h a t i s i n t h e p i c t u r et h a t i s a 3 /dar i v eb e c a u s ei t ' st h e o n l y o n e I
know of that f its good for torqueingthe rod cap. Makesureyou
get it in inch pounds.We're not working on a truck motor.
Okay Pros' now you can come back.
The next step is the fun part. Here you can let your driver,
son or daughter,help. Everythingthat will come ofl or out do it
t i l l y o u h a v ea b a r eb l o c k .F o r t h e b e g i n n e rt h i s w i l l t a k ea b o u t
one (1) hour and for the pro that has been racing Box
Stockers, about 4 or 5 minutes. Now we're ready to go buy
some parts.
Let'sassumethat on the used motor it is a .020overand was
just bored three (3) racesago to that size. I would advisethat
y o u t a k e y o u r b l o c k w i t h y o u t o t h e k a r ts h o p a n d l e t t h e m p u t
a stressplate on it and fit the new pistonto it. More than likely
you can get by with a Wiseco1993P2pistonwhich is .020over.
For piston to wall clearanceyou want .0055to .0065.lf a used
block won't clean at thesespecsthen I would advisehoning it
w h i c h i s a % s i z eo r j u s t . 0 0 5b i g g e r .
a t o u c h m o r et o a 1 9 9 3 P 2 5
This is the neat thing about the Wiseco"Super Stock" Forged
Pistons.They start off at a 1993PSwhich is the standardsize
and then go in steps of .005thousandthsto .030over.
On a new block don't worry about honing it. A new standard
p i s t o n w i l l j u s t p l u g i n a n d w o n ' t b e t o o t i g h t c a u s i n ga n y
cylinderdamage.lf your usedblock hasto go to a 72sizepiston
then use the rings (secondand bottom off the old piston) and
g e t a n e w t o p r i n g f o r a . 0 3 0o v e r p i s t o na n d f i l e t h e e n d g a p t o
. 0 1 0f o r i t .
As far as the rod is concernedthe new Horstmanl-Beamrod
i s t h e l e g a lr o d . P a r t N u m b e ri s H - 4 9 8 1 T
. his rod is trick and
machinedfrom billet stock. lt should last a lifetime.
Camshafts.Here'sa zoo for you.
To make racingfair for all l.K.F.racers,back a few yearsago
we went to hand ground cams and thereare a lot of good cams
thal have been made more for the usage of Super Stock
engines.For the most part these cams are what is called "full
d u r a t i o n "c a m s .B u t o n t h e o t h e r h a n d w h a t y o u h a v ei n y o u r
used Box Stockercould work iust as well. Just set it up differe n t w h e n y o u g o b a c k i n w i t h i t . l n s h o r t ,s e t i t u p s o i t w i l l h a v e
f u l l c a m d u r a t i o n .G i v e i t . 0 0 4t h o u s a n d t h sv a l v el a s h o n t h e
exhaust and intakevalveand you havegot all you can from it.
N o w y o u h a v et o g e ta f u e l t a n ka n dc a r b u r e t i o nk i t .A n y t a n k
t h a t w i l l f i t b e t w e e nt h e s t e e r i n gg a t e a n d s t e e r i n gc o l u m n i s
o k a y b u t , I a d v i s et h a t y o u d o n ' t b u y a n a l l o yt a n k f o r a S u p e r
S t o c k .F u n n yt h i n g sg r o w i n a n a l l o yt a n kw h e ny o u p u t a l k y i n
i t . J u s t g e t a t a n k m a d eo u t o f p l a s t i ca n d y o u w o n ' t h a v ea n y
p r o b l e m sh e r e .
T h e n e x t i t e m o n y o u r l i s t i s t h e c a r b u r e t i o na s s e m b l yF. o r
y o u t h a t d o n ' t k n o w , I h a n d l ea l l t h e R & D w o r k f o r t h e R a c i n g
D e p a r t m e nfto r T i l l o t s o nL t d .W i t ht h e b a b yb o o mo f t h e S u p e r
S t o c k C l a s s I c h a n g e d t h e d r i l l p a t t e r ni n t h e H L - 3 4 8 At o a
p a t t e r nt h a t w a s m o r e s u i t a b l ef o r t h i s c l a s s .T h i s T i l l o t s o n
c a r b u r e t o rp a r t n u m b e ri s H L - 3 4 8 8a n d c a n b e p u r c h a s e da t
a n y o f t h e l e a d i n gk a r t s h o p s .
S o m e o f t h e o l d e rT i l l o t s o nC a r b u r e t o r st h a t a r e s t i l l i n t h e
f i e l d a n d a t t h e k a r t s h o p sw e r e d e s i g n e df o r a L i m i t e dM o d i f i e d M o t o ra n d f o r t h e m o s tp a r tw i l l r u n a b i t o n t h e r i c hs i d e
f o r a S u p e rS t o c k .A n y o f t h e T i l l o t s o nZ / C y c l eg a s c a r b u r e t o r s c a n b e c o n v e r t e dt o a S u p e rS t o c kA l k y s e t - u p T
. hisisnot
t h e t i m e o r p l a c et o g o i n t o t h i s a n d w i l l t a k e a n o t h e rt e c h
A P R I L1 9 9 3I K A B T E R
NEWS
40
N o w c l e a nt h e b l o c k a n d c a m ( a l lp a r t s )a n d m a k eo n e m o r e
d r y a s s e m b l yr u n t o m a k e s u r e t h a t y o u h a v e t h e n e e d e d
c l e a r a n c e sf o r e v e r y t h i n gt o c l e a rr i g h t .O n t h i s r u n ,c h e c kt h e
pop up of the piston.
l f y o u a r e u s i n ga n o v e r s i z er i n g i n y o u r b l o c kt a k et h e p i s t o n
a n d p u s h i t d o w n i n t o t h e b o r ea n d c h e c kt h e e n d g a p . l f i t ' s
t i g h t ,f i l e i t t o a . 0 1 0e n d g a p .Y e s ,y o u c a n p u t i t a t . 0 0 6b u t t h i s
i s a s k i n gf o r i t .
N o w i s a s g o o d a t i m e a s a n y t o l a p t h e v a l v e si n a n d m a k e
sure that they have a good seat. With this all out of the way
c l e a ne v e r y t h i n go n e m o r e t i m e a n d y o u ' r e n o w r e a d yt o p u t
the motor together.
F o r y e a r s I h a v e u s e d P r o T e c G r e a s ea n d a n o i l a d d i t i v e
m a d e b y K a l - G a r dc a l l e d E n g i n e G a r d f o r a s s e m b l yl u b r i c a n t s . E n g i n e G a r d i s a M o l l y t y p e l u b r i c a t i o nc o n t a i n i n g
m o l y b d e n u m .l t c a n w i t h s t a n dl o a d p r e s s u r e si n e x c e s so f
3 5 0 , 0 0 0p o u n d s .T h e b o t t o ml i n e i s t h a t t h i s w i l l h e l pe l i m i n a t e
a d r y e n g i n es t a r t - u pp r o b l e mw i t h t h i s o n t h e p a r t s .l t ' s v e r y
b l a c k i n c o l o r a n d w h e n y o u g e t i t u n d e ry o u r f i n g e r n a i l si t ' s
very hard to get out as Glenn Kenworthy at Piedmont Kart
S h o p c a n t e s t i f y t o . A n y w a y , y o u c a n g e t t h i s K a l - G a r da t
s o m e o f t h e k a r t s h o p sa n d m o s t a n y r a c e c a r s p e e d h o u s e .
Y e s ,y o u r r a c eo i l w i l l l i k e i t a l s o .
Now let's put the motor together for the last time. Take the
r o d a n d p u t a g o o d c o a t o l E n g i n eG a r d i n t h e p i n h o l e o f t h e
r o d a n d t h e p i s t o n .N e x t p u t t h e p i s t o n o n t h e r o d . ( D o n ' t
f o r g e tt h e p i n c l i p s )P u t t h e r i n g so n t h e p i s t o na n d c o a t t h e m
with Pro Tec Grease,Engine Gard or your race oil.
N o w d r o p t h e w e t a s s e m b l yi n t o t h e c y l i n d e r b o r e . J u s t
before you put the rod down onto the crank, put a spot of
E n g i n eG a r d i n t h e m i d d l eo f t h e i n s e r t .A Q - T i p w o r k s g o o d
f o r t h i s . N e v e r p u t P r o T e c G r e a s eo r a n y a s s e m b l yg r e a s e
h e r eb e c a u s ei t m a y p l u g u p t h e o i l h o l e si n t h e r o d a n d c a u s e
t h e i n s e r t st o r u n d r y a f t e ra b i t a n d w i p e t h e m o u t . A l s o d o n ' t
g e t a n y l u b r i c a n ti n t o t h e r o d b o l t h o l e so r o n t h e r o d f i l l e t s .
Next paint the bottom of the insert in the rod cap but don't
g e t a n y o n t h e r o dc a p l i l l e t so r i n t o t h e r o d c a p h o l e s .l f y o u d o
clean everythingwith break clean and start all over. Now take
y o u r r o d b o l t s( l l i k et o p u t j u s t a t o u c ho f b l u e L o c t i t eo n t h e m )
a n d p u t t h e c a p o n a n d s t a r tt h e b o l t s .R u n t h e m u p w i t h y o u r
f i n g e r sa n d t h e n t o r q u e t h e m d o w n t o 1 7 5 i n c h p o u n d s .D o
t h i s i n s m a l l5 l b . s t e p sa t a t i m e f r o m o n e r o d b o l t t o t h e o t h e r .
l f y o u b l u e p r i n t e do u t t h e c a p a n d t h e i n s e r t sa s I e x p l a i n e d
t o y o u a t t h e s t a r t ,t h e s e b o l t s w i l l n e v e rl o s e t h e i r t o r q u e o r
b a c k o u to n y o u . H o r s t m a na d v i s e dt h a ta f t e rb r e a k - i ng, o b a c k
a n d r e - c h e c kt h e r o d b o l t t o r q u e .I d o n ' t d o t h i s . I p u t t h e m i n
t h i s w a y a n d n e v e rp u t a w r e n c ho n t h e m a g a i n .I n m y 3 0 p l u s
y e a r so f r a c i n gr a c ec a r s o r k a r t s ,I h a v en e v e rh a d a r o d b o l t
b a c k o u t o r b r e a ko n m e .Y o u m a k ey o u r o w n d e c i s i o no n t h i s
matter.lf you feel betterabout re-torquingthem go for it.
W i t h t h e r o d b o l t st o r q u e di n t o p l a c es l i p t h e s i d e c o v e ro n
a n d p u t a c o u p l eo f b o l t si n t o i t a n d t u r n t h e m o t o r o v e ra f e w
t i m e st o m a k ed o u b l es u r et h a t t h e r ei s n o b i n d i n go r b u m p i n g
f e e l i n g s l.f y o u ' r ec o m f o r t a b l et h a t e v e r y t h i n gi s c l e a r ,r e m o v e
the side cover.
N o w c o a t t h e c a m a n d l i f t e r sg o o d w i t h l u b r i c a n ta n d a l s o
p u t s o m e o n t h e c r a n k b e a r i n ga n d i n t o t h e c a m b o s s h o l e s .
N o w y o u ' r er e a d yt o p u t t h e s i d e c o v e ro n .
T o r q u et h e s i d e c o v e rd o w n . 1 0 0 i n c h p o u n d si s o k a y b u t I
l i k e 1 2 0o n m i n e .C h e c kt h e e n d p l a y i n t h e c r a n ka n d m a k e
s u r et h a ty o u h a v ea t l e a s t. 0 0 5a n d n o m o r et h a n . 0 1 0e n d p l a y
on a bushingblock.lf you havea dual ball bearingblock no less
t h a n . 0 0 2a n d n o m o r e t h a n . 0 0 5 .
N o w y o u c a n d r o p y o u r v a l v e si n a n d d e g r e ei n t h e c a m o r
s e tt h e v a l v el a s ht o y o ur d e s i r e ds p e c s .O n c et h i s o p e r a t i o ni s
o u t o l t h e w a y l a pt h ef l y w h e e li n t ot h ec r a n ka n d s e tt h e t i m i n g
t o . 2 1 0t o . 2 3 0i n t h e h o l e .( o r 2 4 t o 2 8 d e g r e e s l)f y o u a r e a t
E n t r y L e v e la n d d o n ' t k n o w w h a t I ' m t a l k i n ga b o u t g o b a c k t o
t h e k a r ts h o p a n d a s k f o r a # 4 o t t s e t k e y f o r t h e l l y w h e e l .T h i s
w i l l b e v e r y c l o s et o w h a t i s n e e d e d .
N o wt o r q u et h ef l y w h e enl u t d o w n .H e r eI l e a no n t h i sp r e t t y
h a r d . ( 7 5 f t . p o u n d s )l f y o u d o n ' t h a v e a f t . p o u n d t o r q u e
To carryout this simple modificationto betterlubricatethe
c r a n ki n t h i s b u s h i n gp a r t o f t h e b l o c k y o u w i l l n e e d t w o ( 2 )
s i m p l et o o l s .O n e y o u a l r e a d yh a v ew h i c h i s a n l c e P i c k a n d
t h eo t h e rw h i c ha n y m a c h i n es h o p s u p p l yh o u s eh a s i s a l o n g
shank/s drill bit. The first step is to remove the flywheel
c r a n k s h asf te a l .N o w w i t h y o u r i c e p i c k l a i d f l a t o n t h e s e a l
surfaceat the bottom of the block (turn the block upside
d o w n )m a k ea s m a l lp u n c h m a r k a t t h e b a c k o f t h e o i l t r e n c h
t h a ti sc a s ti n t ot h e b l o c k .T h i s g i v e st h e d r i l l b i t a p l a c et o s t a r t .
N o wp l a c et h et i p o f y o u r d r i l l b i t i n t o t h i ss p o t a n d l i f t i t u p j u s t
enoughso that the bit is not rubbing on the sealsurface.Start
y o u rh o l ei n t h e t r e n c h .
Oncethe holeis started,look into the insideof the block and
position
the angleof the bit so that the hole that you drill
b r e a kosu to n t o p o f t h e c r a n k b u s h i n gp a r to f t h e b l o c ka n d a t
t h eb a c ks i d e .N o w w h e n t h e m o t o r i s r u n n i n gt h e o i l t h a t i s
t h r o w nu p o n t h i ss i d eo f t h e m o t o rc a n r u n d o w n i n t ot h i s h o l e
a n dt h el u b r i c a t i o n
t o t h e c r a n k s h a f ti s d o u b l e d .B o t t o m l i n e :
l e s s c h a n ct oe s e i z ea c r a n k s h a f t(. L o o ka t t h e p i c t u r e s l o r t h i s
modification.)
Thenextstepthat we needto do (and this is legal) is to prep
therodto the crank.The first step is to clean the rod, inserts
a n dr o d b o l t sf r e e o f a l l o i l . B r e a kC l e a nw o r k s g o o d f o r t h i s
operation.The inserts are very soft and here I would use a
papertowel.With all the parts cleanedpul the insertsinto the
rod.Makesurethat you havethe lock tangs in the notchesand
t h eo i l h o l e si n t h e i n s e r t so v e r t h e o i l h o l e s i n t h e r o d . N o w
takeyourcrank and a couple of wood strips f or your vise and
c l a m pt h ec r a n ki n y o u r b e n c hv i s ec l o s et o t h e c r a n kc o u n t e r
w e i g h tN
. e x tp u t t h e r o d o n t h e c r a n k a n d p u t t h e r o d c a p o n
(no oil) and torque the rod bolts down to '100inch pounds.
W i t ht h er o dt o r q u e dt o t h i s m e a s u r e m e ni t i s t i g h t e n o u g ht o
c h e c ka n d m a k es u r et h a t t h e i n s e r t sa r e n o t b i n d i n go n t h e
sideo{ the crank.
l f t h er o df e e l st i g h t o r h a s n o t s i d e m o v e m e n t h e n y o u w i l l
needto takea roundf ile (1/zinch
f ine hole f ile works good) and
filea45oanglechamferon the sidesof the inserts.lf the inserts
arestuckon the rod this is the best olaceto leavethem for this
modilication
becausethey are hardto hold in your hand.lf you
haveto {iletheseinsertsby no meansdo you take sandpaper
to themand try to removethe f ile marks.Just leavethe marks
t h e r eT. h e yw o n ' th u r t a n y t h i n gb u t i f y o u u s e s a n d p a p e yr o u
willgetgrit intothe insertsthat you can't removewhich will eat
theinsertsand the crank up when you start the engine.
Lookrealcloseat the ends of the insertswherethe cap went
down.On the ends of the cap there may be a burr where the
sharpedgesof the cap and rod meet on the inserts.lf there is,
f i l et h i ss p o tw i t ha t h r e es i d e df i l e s o e v e r y t hi n g i s f i t t e dr i g h t .
Cleanthe filingsoff with a tooth brush and break clean.
The next operation is done best with a peek-a-boo side
c o v e rY. o um a yh a v et o g e t a g o o d o n e a n d c u t i t u p . I d i d a n d i t
wasworthit. You only haveto make one becauseit's good for
life.Don'ttry to racewith this peek-a-boocover becauseit will
l e a ko i l o n y o u .
N e x tp u tt h e r o do n t h e p i s t o na n d d o n ' tw o r r y a b o u tp u t t i n g
i n t h ec l i p so r r i n g sy e t .
P u tt h ec r a n ki n t h e b l o c k a n d d r o p t h e r o d a n d p i s t o ni n t o
t h ec y l i n d e rP. u tt h e r o d c a p o n ( m a k es u r et h a t y o u h a v et h e
l i n e - u pm a r k sf a c i n g e a c h o t h e r ) a n d t o r q u e t o 1 0 0 i n c h
p o u n d sN
. o w p u t t h e c a m i n a n d b e s u r e t h a t y o u h a v et h e
t i m i n gm a r k sl i n e du p w i t h e a c ho t h e r .Y o u c a n l e a v et h e l i f t e r s
outfor now.
N o wb o l ty o u r p e e k - a - b o oc o v e r i n t o p l a c e .N e x t t u r n t h e
c r a n ko v e rg e n t l ya n d w i t h a J l a s hl i g h t o r a l i g h tw a t c ha s y o u
t u r nt h em o t o ro v e rm a k i n gs u r et h a t t h e r o d i s n o t h i t t i n gt h e
c a m .l f i t t o u c h e st h e c a m t h e n m a r k t h i s s p o t .
W h e ny o u a r e s u r e y o u h a v e a l l t h e h i t p l a c e s m a r k e d ,
r e m o v ey o u r p e e k - a - b o oc o v e r a n d p u l l t h e c a m , r o d a n d
c r a n ko u to f t h eb l o c k .N o wy o u c a n ' tt o u c ht h e r o d b u t y o u c a n
f i l et h ec a ms o t h e r o d w i l l c l e a ri t .T o m a k es u r et h a t y o u d o n ' t
r u ni n t oa n y t h i n gh a v ea t l e a s t1 / 1 6i n c h o f c l e a r a n c eb e t w e e n
a l lm o v i n gp a r t s .
41
K A R T E RN E W S/ A P R I L1 9 9 3
w r e n c h t h i s c o m e so u t t o a b o u t a l l y o u c a n p u t o n i t w i t h a 3 / a
b r e a k e r b a r w i t h o u t p o p p i n g a h e r n i a .W i t h t h e f l y w h e e l
t o r q u e dd o w n , p u t t h e c o i l o n . W i t h a b u s h i n gb l o c kg e t i t . 0 1 2
a i r g a p .l f i t ' sa d u a lb a l lb e a r i n gb l o c kb e t t e rg o f o r . 0 1 6o r t h e
f l y w h e e li s l i a b l et o r u n i n t ot h e c o i l w h i c h i n t u r n c a n k i l lt h e
c o i l o r f l y w h e e la n d t a k e a w a y p r e c i o u sh o r s e p o w e r .
Y o u a r e n o w r e a d yt o t o r q u et h e h e a dd o w n .l f y o u p i c k e du p
o n e o f t h e t r i c k a f t e r - m a r k eht e a d g a s k e t st h a t h a s t h e b l a c k
center in it or you are using one of the stock fiber Briggs
g a s k e t s y, o u b e t t e rg o f o r 1 2 5i n . p o u n d so f t o r q u e .A n y m o r e
t h a nt h i s a n d y o u a r e l i a b l et o s q u e e z ey o u r s e l fr i g h to u t o f t h e
T e c h B a r nw i t h l e s st h a n . 0 4 3m i n i m u mo n t h e h e a dg a s k e t .l f
it's one of the older stock head gasketswith the white centerin
i t o r s o m e o f t h e a f t e r - m a r k etth i c k e rg a s k e t s y, o u c a n g o f o r
150 inch pounds on these to get a touch more compression.
W i t h t h e e n g i n e a l l b a c k t o g e t h e rw e c a n n o w t u r n o u r
attention to the carburetion part of the operation.As I state
b e f o r e ,t h i s i s n o t a T i l l o t s o nC a r b u r e t o rT e c h A r t i c l eb u t ,w e
have to hit a few high spots or that lunny thing with two {2)
n e e d l e ss t i c k i n go u t o t f i d d l ew i t h ,t h a t h a sa n L o n o n e o f t h e m
a n d a n H b y t h e o t h e ro n e , i s g o i n g t o s e n dy o u t o t h e F u n n y
Farm.
lf your carburetor is just out of the box (brand new) you
better take it back to the kart shop and havesomeoneknowledgeablethere set the pop-off pressurefor you or get a popo f f g a u g ea n d c o m e h o m e a n d s e t i t y o u r s e l f .Y o u w a n t t o s e t
the pop-off pressureat 8% pounds. lf this is your first trip into
t h e T w i l i g h tZ o n ey o u b e t t e rm a k ea n o t h e rt r i p b a c kt o t h e k a r t
shop and get you a handfull of pop-off springs.
l f t h e T i l l o t s o nt h a t y o u h a v e i s f r o m t h e H L S e r i e so f H L 3394 thru HL-3488,then what you want is part #EC-001popo f f s p r i n g s . l f t h e c a r b i s a n o l d e r s e r i e st h e n a s k f o r p a r t
#248-299pop-off springs.When settingthe pop-off pressure
a n d y o u c u t t h e s p r i n gt o g e t a l o w e r r e a d i n ga n d y o u g o t o o
f a r ,n e v e rs t r e t c ht h e s p r i n gt o g e t b a c ka h i g h e rr e a d i n gA
. lso,
i t ' s n o t w i s e t o h a v ea t a i l s t a n d i n gu p f r o m a c u t s p r i n g .Y o u
needto take a pair ol smalltweezersand rebenda f lat end back
o n t h e s p r i n g .W i t h t h e p o p - o f f p r e s s u r es e t w h e r ei t p o p s o n
872lbs.and holds on 7% lbs. you havea startingspot for track
tuning.
N o w c h e c kt h e p u l s eh o l d t h r u t h e m a n i l o l da n d m a k es u r e
t h a t i t i s o p e n a n d a t l e a s t% i n c h i n s i z e .B o l t t h e c a r b t o t h e
m a n i f o l da n d m a k es u r et h a t t h e p u l s eh o l e i n t h e m a n i f o l di s
i n l i n e w i t h t h e p u l s eh o l e i n t h e c a r b u r e t o rN
. owyou can bolt
the assemblyup to the block.
H o o k u p t h e p u l s e l i n e f r o m t h e m a n i f o l dt o t h e f u e l p u m p
and the fuel outlet spigot from the pump to the carb cap. Now
all you haveto do is hook the f uel line from the pump to the fuel
t a n k . D o n ' t f o r g e tt o p u t a f u e l f i l t e r i n t o t h i s l i n e .
We're now ready to go to the race track for your Maiden
Voyage.Once at the track,check and makesure that you have
put oil back into your new motor. Don't laughl Some of the
b e s th a v el e f t t h eo i l o u t o f t h e m .O n a n e w m o t o r I l i k e t o b a r r e l
roll the kart to pour oil up into the top of the motor. This way I
know that the motor won't start dry. Once this is done, set it
backon the ground.
Now turn your attentionto the carb.Setyour low side needle
a t 1 % t u r n s o u t a n d t h e h i g h s i d e n e e d l ea t 1 t u r n o u t . T h i s
s h o u l db e a g o o d e n o u g hp l a c et o g e t t h e m o t o rt o f i r eo f f. T h e
idle screw at the bottom just set it so that it cushions the
t h r o t t l ev a l v e .N e v e rh a v et h e c a r b s e t w h e r ei t w i l l i d l e .l f y o u
have this screw set where the butterfly is open any amount,
y o u w i l l h a v ea l e a n o u t w h e n y o u l i f t y o u r f o o t .T h i s l e a no u t
w i l l c a u s et h e m o t o r t o b o g w h e n y o u c o m e o u t o f a t u r n o r o f f
t h e c o r n e r .A n o t h e rt h i n g t h a t y o u d o n ' t d o i s s t a r tt h e m o t o r
u p a n d t r y t o l e t i t r u n f o r a n y l e n g t ho f t i m e o n t h e k a r ts t a n d .l f
y o u d o y o u w i l l f i l l t h e e n g i n eu p w i t h a l k y .W i t ha b i g l o a do f
a l k y i n t h e b o t t o m y o u w i l l w a s h t h e c y l i n d e rw a l l sd o w n a n d
t h i s c a n a n d w i l l c a u s ec y l i n d e rw a l l d a m a g e P
. l u s ,y o u r o i l
w o n ' t m a k e i t p a s s e dt h e b e e p e rw h e n y o u g o u p o n t h e s t a r t
line.
APRIL1993/ KARTER
NEWS
42
T H E F O L L O W I N GR U N N I N G S T E P S A R E T H E S A M E
P R O C E D U R EF O RA N Y 4 / C Y C L EE N G I N E ,S U P E RS T O C K ,
L I M I T E DM O D I F I E DM
, O D I F I E DB R I G G SO R O P E NW I T HA
T I L L O T S O NC A R B U R E T O R .
N o w w e ' r er e a d yf o r t h a t f i r s t M a i d e nV o y a g e .P u t y o u r r a c e
gear on and set the kart on the ground pointed toward the
t r a c k . l f y o u ' r es t a r t i n gt h e k a r t w i t h a r o p e s t a r t e rm a k ei t a s
e a s ya s p o s s i b l eo n t h e g u y o n t h e o t h e re n d o f t h e s t a r t e rT. h e
f i r s t s t e p i s t o m a k es u r e t h a t y o u d o n ' t h a v ey o u r f o o t o n t h e
t h r o t t l eb e c a u s et h e t h r o t t l ev a l v em u s t b e a l l t h e w a y c l o s e d
s o t h a t i t w o r k sl i k ea c h o k ea t t h i s t i m e .W i t h t h e t h r o t t l ev a l v e
c l o s e d ,t h i s c h o k i n g m o d e i n t h e c a r b u r e t o rw i l l p u l l t h e f u e l
u p t h e l i n e t o t h e c a r b u r e t o rA
. s y o u r h a n d l e rp u l l st h e s t a r t e r
r o p e a n d t h e m o t o r t u r n s o v e r y o u w i l l s t a r tt o s e e f u e l l e a v e
t h e t a n k a n d h e a df o r t h e f u e l p u m p .
l f e v e r y t h i n gi s d o n e r i g h ta b o u tt h r e e( 3 ) g o o d p u l l sa n dt h e
f u e lw i l l b e u p t o t h e c a r b u r e t o rA
. s y o u s e et h e f u e l g o i n t ot h e
carburetorthe next move is up to the driver.As your handler
p u l l st h e s t a r t e ro n e m o r e t i m e y o u a t t h e s a m et i m e o p e nt h e
t h r o t t l ea l l t h e w a y a n d l e t a i r i n t o t h e m o t o r .A t t h i s p o i n tt h e
motor should light.With a seriesof sharp stabson the throttle,
move the kart out onto the track.
Now with a Super Stock becausewe are using a Box Stock
c a m a n d i t h a s t h e e a s y s p i n b u m p o n i t , t h i s c a u s e st h e
carburetorto be a touch lean acting on the bottom. Onceyou
are under movementfind the spot and the throttle position
where the motor is running smooth not flat out but, at a moderate pace. Neverlet the motor run at any spot where thereis
a n o v e r r i c h c o n d i t i o no r y o u w i l l g e t a l k y i n t o t h e o i l .
Now go for a few laps and let the motor get warmed up.
R e m e m b e r t h i sl s a n e w m o t o r a n dw e d o n ' tw a n tt o h u r t i t .F o r
the engine to break in right it has to be worked.
At this point on every straight-away,stand on the throttle
a n d l e t t h e e n g i n ep u l l u p t h r u t h e R . P . M .r a n g e ( 5 , 5 0 0p l u s ) .
Now chop the throttle and let it back down under compress i o n .W h e n y o u c h o p t h e t h r o t t l el i k e t h i s y o u p u l l o i l u p i n t o
the motor and it helps keepthings wet inside.Now if you stand
o n t h e t h r o t t l ea n d t h e m o t o r f a l l s o n i t s f a c e ( b o g s )t h i s i sa
sign that the carburetoris set too lean off the low side adlusting needleO
. p e nt h i s n e e d l eu p a n o t h e r% t u r n . N o w s t a n do n
i t a g a i n .l f i t s t i l lb o g s ,o p e n t h e l o w s i d e n e e d l ea t o u c h m o r e .
l f y o u f i n d y o u c a n ' to p e n t h e l o w s i d e n e e d l ee n o u g ht o c u r e
t h e b o g p r o b l e mp a s t t h r e e ( 3 ) t u r n s o u t ( a n y m o r et h a nt h i s
and the needle will fall out) this is a sign that the pop-otf
pressurein the carb is set too high (most of the time.)
O n t h e o t h e r s i d e o f t h e c o i n i f t h e m o t o rj u s t f l a t w o n ' tp u l l
a n d h a sn o p o w e rw h e n y o u s t a n do n t h e t h r o t t l et h i sc o u l db e
due to too low of a pop-off setting.Or the needleand seatare
l e a k i n ga n d w o n ' t s h u t o f f i n s i d eo f t h e c a r b u r e t o rT
. hecure
here is pull the pump stackoff and makesurethat you haveput
t h e n e e d l eb a c k i n t o t h e s e a tw i t h t h e s h a r pe n d d o w n i n t ot h e
brassseat. Don't laugh! I've had two (2) carburetorssentinto
me for rebuildsthat had this mistakemade.
lf the spring is in placeand all looks well,removethe fulcrum
a r m s p r i n g a n d n e e d l ef r o m t h e c a r b . N e x t t a k e a Q - T i pa n d
spin it into the brass seat with your fingers and clean the
bottom of the seat.There could be a spot of trash herethatis
holding the needleup and not letting it seat.With the carburet o r o n t h e e n g i n e u s e W D - 4 0t o c l e a n a n d f l u s h o u t t h e c a r buretor.This way if some of it gets into the engine it won'tbe
h a r do n t h e l u b r i c a t i o n .
W e tt h e g a s k e t sa n d p u m p sw i t h s o m eo i l o r y o u r W D - 4 0 a n d
put the pump platesback onto the carburetor.Be surethatyou
d o n ' t g e t o n e o f t h e g a s k e t sb a c k o n t h e w r o n g s i d e o f t h e
d i a p h r a h mo r o n e o l t h e s n a k e s k i n p u m p s . S t a r t i n ga t t h e
b o t t o m o f t h e c a r b u r e t o ry o u h a v et h e g a s k e tf i r s t t h e nt h e
b l a c kd e m a n dd i a p h r a g ma n d t h e f i r s t p u m p p l a t e .T i g h t e nu p
the screwsand check the pop-off pressure.Makesurethatthe
c a r b u r e t o rw i l t p o p o n 8 % l b s . a n d h o l d o n 7 t o 7 % l b s .N o w
you're readyto go back out onto the track and dial in the
c a r b ur e t o r .G o b a c kt o a s t a r t i n gp o s i t i o nw i t h t h e n e e d l eas t
'1
7 et u r n s o n t h e l o w s i d e a n d 1 t u r n o n t h e h i g h s i d e .
A sa r u l eo f t h u m bw i t h a n y o f t h e n e w e rs e r i e sH L c a r b u r e t o r so u t o f t h e b o x a n d n o t b l u e p r i n t e dt o a c e r t a i nt y p e o f
e n g i n eb u t ,w i t h t h e p o p - o f fp r e s s u r es e t a t 8 7 2l b s .t h e f o l l o w i n g s e t t i n g sw i l l b e r e a l c l o s e : S U P E R S T O C K - L o w s i d e
n e e d l e1, 1 / z l o 2t u r n s o u t . H i g h s i d e n e e d l e ,% t o 1 t u r n o u t .
L I M I T E DM O D I F I E D- L o w s i d e n e e d l e ,1 1 /lao 1 1 /tzu r n s o u t .
H i g hs i d en e e d l e1, t o 1 1 A
t u r n so u t . M O D I F I E DB R I G G Sa n d
u s et h e b i g g e rH L - 3 5 5 Af o r t h e s eh e a v yb r e a t h e r sa n d
OPENS
t h en e e d l e w
s i l l s e t c l o s et o t h e s a m et u r n s o u t a s t h e L i m i t e d
M o d i fe d s .
As you open the low side needle more to cure the bog and
l e a np r o b l e m so f l t h e b o t t o m y o u a r e a l s o m a k i n gt h e w h o l e
rrange
o f t h e T i l l o t s o nC a r b u r e t o rr i c h e r .( K e e pt h i s i n m i n d )
Okaylet'ssay that you havegot the carburetorset so that it
p u l l sh a r do f f t h e b o t t o mb u t s o m e w h e r eu p i n t h e R . P . Ms. c a l e
t h em o t o rj u s t c h o p s p l u m b o f f t h e n c o m e s b a c k o n b y i t s e l f
w i t ht h et h r o t t l ew i d e o p e n .T h i s i s a s i g n t h a t t h e m o t o r i s t o o
richon the top end and the cure here is to take the high side
n e e d l ien a b i t a t a t i m e t i l l i t w i l l r u n c l e a no n t h e t o p .
O n c ey o u h a v e f o u n d t h e n e e d l ep o s i t i o nw h e r e t h e c a r b u r e t orru n st h e f u l l l e n g t ho f t h e f a s t e s ts t r a i g h t - a w a yr,a z o r
s h a r pc l e a no n t h e t o p e n d , t h e n c o m e s b a c k t o p a r a d el a p
speed.At parade lap speed stand on the throttle and make
s u r et h a tt h ee n gi n ed o e s n ' tb o g . l t m i g h t b e c a u s ea s y o u t o o k
someof the rich setting off the high side needle you also
leaned
o u t t h e b o t t o mj u s t a t o u c h . S o l u s t o p e n t h e l o w s i d e
e n o u g ht o c u r e t h e f l a t s p o t o f f t h e b o t t o m .A t t h i s p o i n t t h e
h i g hs i d en e e d l es h o u l ds t i l l b e o k a y a n d a s t h e m o t o r c o m e s
u pi nt e m p e r a t u raen d a t r a c i n gs p e e d sy o u o p e nt h e h i g h s i d e
needlejust a touch at a time to control engine heat.
Howhot is too hot? Well each to his own here but I feel that
anythingover325o is too much.
A f t e rt h e d a y o f r a c i n gi s o v e r h o w w e l l y o u r T i l l o t s o nc a r b u r e t oar n d f u e l p u m p w i l l w o r k t h e n e x t d a y o r n e x t w e e k s
r a c ei s a l l u p t o y o u . T h e m o r a l o f t h i s s t o r y i s t h a t a l k y a n d
a l l o yd o n ' tm i xw e l l .I n s h o r t ,i f y o u l e ta l k ys e t i n t h e c a r b u r e t o r
or luel pump for any length of time you will start a garden
g r o w i n go f f u n n y g r e e n s t u f f a n d w h i t e a s h d u s t . T h e m o r e
w a t e or r t h e o l d e ry o u r a l k y i s t h e m o r ec u l t u r ey o u g r o w .T h e
o n l ys a f ew a y o u t f o r t h i s p r o b l e m i s t o f l u s h e v e r y t h i n go u t
w i t hg a sw h e nt h e r a c e sa r e o v e r .l t ' se v e na g o o d i d e at o p u t a
s p l a s ho f y o u r o i l i n t o t h e g a s f o r t h i s o p e r a t i o n .
H O WT O ' S :P u l lt h e f u e l l i n e o f f o f t h e b o t t o mo f t h e p u m p .
Nowtakean emptyoil bottleor somethingand put about a pint
o fg a so i l m i x i n t oi t . D r o pa p i e c eo f f u e l l i n ei n t ot h e b o t t l ea n d
w i t ht h e k a r t u o o n t h e s t a n d o r w i t h t h e r e a r w h e e l so f f t h e
g r o u n dp, l u g t h e l i n e i n t o t h e f u e l p u m p .
N o ws t a r t h e e n g i n e .A f t e r i t r u n sa b i t t h e m o t o rw i l l s t a r tt o
r u nv e r yr i c h .A t t h i s p o i n t , k e e p t h e m o t o r r u n n i n gb y h a n d
a n da tt h es a m et i m et a k et h e l o w s i d en e e d l ei n a l i t t l ea t a t i m e
to leanit out so the motor won't load up and die. I keep my
m o t o r sr u n n i n gl o n g e n o u g ht o g e t a g o o d 8 o u n c e so f g a s r u n
t h r ut h e m .T h i s w a y I k n o w t h e r e i s n o t a l k y l e f t i n t h e f u e l
p u m po r t h e c a r b u r e t o ra n d i t h a s a l s o h e l p e dt o p u t s o m e
lubrication
back into the top end of the motor.
W i t ht h e c a r b u r e t o frl u s h e do u t p l u g t h e f u e l l i n e b a c k i n t o
t h ef u e l p u m p s o y o u w o n ' t d r a i n a l k y d o w n y o u r p a n t l e g
w h e ny o ul o a du p t h e k a r tf o r t h e t r i p h o m e .N o w y o u c a n t a k e
y o u rk a r th o m e ,w i p e i t d o w n a n d w a i t t i l l n e x tw e e k e n d sr a c e .
K i n do f n i c et o g e t i n s o m e T V t h i s t i m e ,w a s n ' ti t !
T i l lt h e n e x tt i m e :K e e py o u r F u e l D r y !
TechEd
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TechnicalHotfine-615/446-6807
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aa
t
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Y m\.tb
l7
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1309Old CharlottePk.
Dickson,Tfl. 37055
43
K A R T E RN E W S/ A P R I L 1 9 9 3
Trick, hard to find light weight starterrachetfor Box Stockers.
Peek-a-Booblock so you can seewhereclearancewill misscamshaft
Valveguide installationtool kit.
-
: ri:ri
'r'
I ,
T i l l o t s o nC a r b u r e t o K
r i t n e e d e dw h e n o o i n o f r o m B o x S t o c kc l a s s e s
t o S u o e rS t o c kc l a s s .
W a l b r ol u e l p u m p f o r a l l S u p e rS t o c k ,L i m i t e dM o d i l i e d
B r i g g sM o d i f i e do r O p e n C l a s sE n g i n e s .
Ui,
[4.
A P R I L1 9 9 3 / K A R T E RN E W S
rEcHNoLoo
CAM
RACING CAMS
Propercam selectlonis averyimportantfactorin
buildinga successfulraclngenglne.To have a
winning "combination,"you should select the
profilethat will be compatiblewith the othercom.
ponentsin your engine as well as the type of
tracks you will be racingon, e.g. short dirt ovals,
sprinttrackswith longstraights,trackswith many
t i g h tt u r n s ,e t c ,
parts
and
The
tvo
nost
inportant
of
any
engine
are
the
Camshaft
the carburetion
and
Carburetion.
handles
the
air
flov
the fuel
nixture
to the engine.
Thls
is
half
of
the story.
flos
vith
the
In short,
the rnore air
proper
of
anount
fuel
mixed
into
1t
ls
relation
to
hov uruch
1n direct
your
engine
can produce.
horsepover
half
of this
the
The
other
story
The
camshaft
is
is the can6haft.
factor
when
1et
conbrolling
in
and how nuch of this
air
flow
is
into
the
al.so controls
leaves
engine.
It
the engine.
r when it
(2)
are tro
different
There
flelds
of
knowledge
One
in a Canshaft.
how
to
it
a given
is
nake
and
the
other
the nost
out
of
is hov to get
ue
work to
canshaft.
What
are going
to learn
is hor to nalre any canshaft
potential
your
best
its
and adjust
1t around
to flt
Race Track
needs.
The first
step
to select
is
the
needs
of
the
motor
a cam that
fits
you
want
that
Uo bui1d.
a can
is designed
fn
shortr
that
to nake its
pover
at
lorer
R.P.M. ' s means
that
the
torque
is
better
at
the
lower
R.P.M.
curve.
peak
you needr
you have
Now if
horsepower
is chat
then
to
the
turn
motor harder.
cam has
The
to
be
designed
to turn
these
higher
R.P.M. ts
give
and it
vi11
up sorne of the lover
end torque
to achieve
this.
you
Hon can
have
the
best
of
Worlds?
Well
kner.
both
if
ve
thab
answer
$e
would
all
be
ZiLL ionalres.
But
vlth
a good understanding
of
the canshaft
we can nove it
up
or
depending
dorn
on ruhere
makes
its
it
power
your
achieve
to
a faster
conbination
type
for
of race
track.
This
nore
takes
than
a little
blt
of
tiure
to understand
and a touch
of math,
get
but ve will
This
holds
there.
for
boLh Stock
and Modified
Engines.
This
is the
flrst
CBIfTBR LfNBS:
step
that
frm going
to try
and teach
you and ho$ they
your
affect
engine.
the
mosU part,
canshafts
For
the
cent,er
lines
can't
be
changed.
This has been conLrolled
by the
Carn Grinder
that
made
We
the
canshaft.
can
advance
the
cams
center
lines
for
nore
torque
or ne can
retard
them
more top end.
for
On a Limited
Modified
or 0penr r{€ can do this
by moving
the position
gear
of the crank
one vay or the obher.
This
can
also
be
done by having
gear
you move it
an adjustable
on
the
camshaft
that
lets
one way or the
other.
gears
Camshafts
with
adjustable
on
them
are
nake.
expensive
to
Horstman
goes
Mfg.
simpli f ied this
cost
by uraking a cam gear
the
that
on
(3)
crank
with
three
notches
in it
for
bhese engines,
The first
noLch
is
marked vith
an'O'and
is straight
up cam timing.
In
short,
this
is
the
45
position
all
can
for
nark
Canshaf,t
and shere
stock
the
tinlng
on a Briggs
grinders
grlnd
part.
their
cams otE of for
the nost
notch
in this
The gear
is also
narked
nith
an uAx on 1t and rhen put
you advance
the
advance
the center
3o.
If
it
vill
lines
and the canshaft
it
soone!
rill
open the intake
earlier
and close
camshaft
thls
valve
then
the
If
aff ects
exhaust
valve
the sarne rray.
produce
end torque.
Horever
By advancing
the c?ntr you ri11
more
Ios
pover
gear
end
notch
in it
top
ri11
be
hurt.
also
has another
The
can
you
position
marlced with
retard
an ilRn.
When put
on the
cranlc
in
this
and
top
end torque
the ca& by 2o.
RetardinS
the can increases
nidrange
botton
but hurts
end performance.
you can
tuning
edge
So again
see
but a valuable
this
is
a trade
off
poyer
nore
for
to flt
a certain
of racing
surface
or track.
type
Now in a Box Stocker,
re canrt
for
thingr
this
do this
because
one
gear
ground
Nunbet
it
is
illegal.
2,
if
the
rlght
canshaft
is
r rhere
will
nake the pouer
is needed
sin
1t vonrt
nake tech.
that
to
vith
today,
Nor
sone
cans do have enough room ln then when nade or wear
on then
that
you can hand select
gears
1t as
stoclc
crank
and advance
the can or retard
nruch as 1o.
york
your
personal
I.Iith
E.C.
Tuning
Book,
can
there
is one
of
ny
print
you
down
shop and
sheets
and
I
advise
that
take
it
to
the local
goes on.
have a box of then
run
off.
You will
need then
as tine
your
you
probably
Since
start
rords
the
of
have
seen
the
racing
'tCenter
you
Lines"
and
also
have heard
rords
at
theee
vhispered
to
the
you.
your
poker
you
track,
Or
maybe
race
even
asked
of
Wlth
best
face
you knov al1
you
smlle
and act
like
in
llfe
the Speed Secrets.
But
true
don I t knov what the hell
they're
tallclng
about.
you
quit
tf
Well
already
t<nor all
the
here
and read
the
drBy€ES r
y
o
u
section
on Ti llotson
Carburetors
and
if
knov
all
the
ansuers
there
give
you.
ne a call
then
I may have a job
for
because
areas
Centerlines
are one of the noat
misundersbood
of
a can.
There
(2)
are really
centerlines
lnvolved.
tuo
(degrees
and
The LOBE CENTERLINE
betveen
lntake
exhauet
can lobes)
which
by the cam grlnder
1s fixed
and cannot
be
tvisting
changed
without
you
the
can.
Thls
should
never
do because
it, s alnost
imposslble
to get
p
r
o
p
e
r
the can straight
again.
The
uay
to
change
this
lobe
center,
tf
needed,
be
have
a cam grlnder
vould
to
regrind
and
advance
or
retard
you vant
whichever
lobe
bo nove.
The OVERALL CENTER LINE 1s the
second.
(2) ways to flgure
Norr to make
a blt
are tuo
things
tuzziert
there
lobe
cen ters.
vay ls
and
,050 off
valve
opening
closing
This
vould
0ne
tine.
be
rith
can
up and ready
to race.
The other
the
set
way 1s.050
before
nax
lift
max 1ift,
uith
no
and.050
after
clearance
ln
the
valve
train.
If
straight
upr then both
the can is ground
nethods
vi11
check
out
the same.
But tf
aoneone
threw
a curve
at you and ground
the ca!n aaymmetricalr
llke
some of niner
ranp speed or
duration
to nake a faster
nore
at one or nore
places
you
in
cdrnr then
will
come up vith
the
center
and both
tro
lines
are vorth
lcnoring.
you yet?
If
I
haven't,
Have I lost
donf t
sorryr
But there
f ri11.
is light
at the
end of the tunnel
and you vi11
see it
ln time.
yorlc
way
figure
The
first
to
lobe
centers
1s the ray
on your
sheet
and bhe one that
u
s
e
t
h
e
m
o
s
b
r
h
i
c
h
i
s
I
figured
off
the nose of the can.
produce
you
This
uay vill
the needed
infornation
need
Box
for
Stockers
and Hot Rods.
We will
uay first
do
it
this
and then re will
do it'at
.050 off
the
valve
opening
at what this
information
and look
te11s
ua.
First
off,
refer
back to
Blueprlnt
Bor
Part
Stoct
*2 on rEoy To Set
you have perf ect
Up lour
Degree l{heel
On Perf ect
Top
Iread Centerr .
Af ter
your
put
your
T. D. C. set
Degree
on
Wheel,
exhaust
intake
in
and
test
46
(Valves rith
valves rith,000
dovn ao they
valve lash.
heads cut
von't
touch seats )
Nor nove your
Dlal
out
Indlcator
over
to the tntake valve and fill
the vork sheet (on the rtght
fift
and back
.010 valve
eide)
etartlng
at
against
the
to
.0f0
off the seat.
OD Box StockerB check your york sheet
Tech reading
to make aure your
Once you have these lift
can ls
1egal.
degree numbers 1n, go back and Dake 6ure T.D.C. Is sti11
spot on.
Next nove to the left
data
that
slde of the sheet
and put
in
the
your
your dial
fits
can on Intake
and Exhaust Valves.
Thls is done vith
indicator
and your test valve rith
no laeh ln 1t.
your
On the intake
say dovn to
elde r atart
and york
at 34o B.T.D.C.
28o B. T. D. c.
SATPLE Cll{:
tC
I.O.
LISE
30
.oo7
*327
BUXP
.oog
I.C.
106
Hov in the he11 did I get theBe nunbers?
set.
Okay.
T.D.C. ls
The
dial indtcator
ls
setting
on top
of
lntake
valve
and set on .000.
the
Nor I turned
the crank over (dtrectlon
the notor
runa)
untll
I got to 30
polnt
B.T.D.C.
At this
look at the lndlcator
and tt shovs that
the valve
lifted
.004.
In short,
thls
ls
telllng
ne tf I take a ney valve and put
it in ny valve lapplng
block and renove enough off the end of
the sten to
have.007
valve laEh, I slll
have an Intake 0pening of 30o B.T.D.C.
Nov your rork
eheet rllI
look llke
thlsr
I.O.
30
LISB
BT'XP
I.C.
. oo7
Turn the motor
over
until
the lntalce valve goes up and over the nose
of the cam and starts
conlng back dorn the back elde.
At the
nonent
it
ghov .015 on the indlcator.
hange on the
Ez Spin
Bunp.
Xt ulll
Thls
neans take the .007 off
for the valve
lash and you vi11 have .008 EZ Spin
ghorlng.
Bunp left
Your York sheet yill
shov thler
I.O.
30
LlSf,
.007
EUXP
.008
f.C.
Very
slouly,
you get
turn your notor over and stop .007 Just
before
x
y
o
u
r
back to
0, on
indicator.
d lal
nunber dovn on your uork
Write thls
sheet .
Your vork sheet shoul.d loolr Iike
thie:
I.O.
30
LfSE
.007
EUl|P
. oo8
I.C.
l06
This last
nunber ls vhere karting
can grinders
and nyself
differ
on
hov to
call
it.
Although
re're
both saylng the sane thing,
ny rray is hor
you look at a raclng
cam for
i
c?!r
Llnlted
llodlfied
or Open.
In short,
(thatrs
the intake
seal ls A.B.D.C.
vhen conpresslon
and pouer
starts
to
yent
be made,
A.B,D.C.
not
B.T.D.C. )
I
thlnk
nost karting
can grlnders
yent to B.T.D.C.
karting
can grinders
getting
keep you fron
to
too
Juet
y
o
u
I
r
e
g
l
v
i
n
g
vorried
about
hon nuch
up due to the E Z Spln Burnpr which
is a very lnportant
get
tuning
and ce vilt
factor
back to that
on
later
your englnes poverr
how it affects
you get
your
After
Intake
done nove over
layout
Uo your
Exhaust
Valve and f111 out that part of the vork sheet startlng
at 65o B.B.D.C.
and uork your yay dorn 2o at a tine until
you get bhrough 6oo B.B.D.c.
47
'rwhat doee 20 one
yourre
probably
By this
tine
saying
to yoursetf
possibfy
r.ay or
other
nean to ne and nhat
tt
naker?
the
difference
could
This
is the easiest
Hay
for
ne
explain
hor
lnportant
lt
19.
Put
to
your
Wrlte
dial
indicator
on the valve
and check hors f ar it
tnoves in 20.
meaaurement
dorn.
that
Now move your
lndicator
over
to
the piston
and
your
measure
that
novement
in 20 of travel.
motor
R.P.M.
at
Figure
5r400
and 15 laps
on a 30 second
track.
piston
you had in that
Nov
look
at
how many feet
making
of travel
pouer,
valve
letting
ln fuel
20 one
or exhaust
out.
Nou you can see that
you.
Tay or the other
makes a hell
of a differencer
donrt
go back to center
Letrs
how to figure
then
and how to put
lines
and
this
inforuration
to rork
us.
for
First
letrs
look
at the rray to figure
center
lines
by
the
format
on
the vork
sheet.
your
perfect.
Go back
and
double
check
make
it's
T.D.C.
to
sure
Again
ve wl11 use an EC *327 Can for
our sanple.
r0r
perfect
your
your
with
T.D.C.
and
Degree
Wheel
on
nove
dial
indicator
over
to the
top of the
lntake
valve.
Turn your
notor
tifl
over
you get
your
to nax valve
lift.
Reset
indicator
to r0n.
Norr baclr
Okay.
r 0r .
the
motor
up
ti 1f
the
indicator
has
dropped
.075 fron
Next
the
j
u
s
t
y
o
u
g
e
t
turn
the urotor
foruard
slonly
untll
back to
.050 before
the
'0u.
york
This
rill
be 55.
Now vrite
this
number
on your
sheet
in
the
f i rst
b1 ank.
IIf T.
I 800
LOBE
47
CTN LIilE
oPen
Turn
the notor
forrrard
until
the valve
lifts
u
0
u
p
a
s
s
e
s
a
n
d
lift
the
and starts
back docn the
careful
and stop DBAD OIf TEB.05O llABf,.
Nov write
your work sheet.
Your sheet should look like
this
now:
IIf T.
I 800
LOBE
4''
the
other
this
CfB LIIfE
22.5
lndlcator
slde.
nunber
to nax
Be very
dorn
on
open
=
Nou ninus these two numbers fron 180o 47
22.5
t10.5
open.
Move this
open nunber to the next line:
110.5 divided
by / = 55.25.
Now take your 55.25 and move it dovn to
the
next
line
and the first
= _____- CTR Line A.T,D.C.
space:
55.25
Nos go back up to
the
top and pick up the biggest
ndnber
and put
it
in
the
next
6paces
55. 25 + 47 = 102.25
cTR.
Add these tuo numbers and you have an Intake
Center Line of 102.25 A.T.D.C.
Go through
these
same steps
with
the
exhaust
valve
to
flgure
ite
lobe
and
center
line.
Now to
find
add it
to the
the canshaft
center
exhaust
center
line.
102.25
+
llo.75
dlvlded
line,
by
I
=
take
the
intake
lobe
center
106.5
gives
us a lobe
center
line
of 106.5.
When you
start
you
to
cotnpare
lobe
centers
vill
find
for
the
part
that
they
will
be very
close
to
each
other.
Most
Briggs
cans
have a lobe
center
of
106o plus
or minus
2o.
Now find
the overall
cam center
line
by subtracting
the
i ntake
center
line
from
the exhaust
center
line.
Here we have
:
This
BI CTL
110.75
IilT CTL
LO2.25=
B.T.D.C.
8.5
48
uost
vill
lobe
For the
most part
the can rlll
nake.
O =
tbe
The
closer
blgger
get6
this
nunber
to '0u
the
the nunber
it
the more torque
nore
will
R.P.M.
nake.
Is
lOrOItE = l4
l. P.l{.
point
Another lnportant
nose duration
to
look
at
1e the overall
at
.050 narks (flrst
the
llne
on your rorlc sheet).
The bigger
this
number
is
bhe nore porer you vill
nake on top end.
nunber
The narrow or smaller
of degrees here the engine v111 turn
up faster
and have a touch nore low
end pover.
you ehould
Now
have a better
understandlng
of hor
center
lines
affect
the porer of your englne.
The next key factor
ls the duration
of the c?D.
your
Go back to
vork
sheet
and look at the total
on the first
line.
This
is
the
anount
duratlon
of
of
the can noae spread.
More duration
leads
to nore
R.P.lt{. and peak poyer.
In
shortr
the valves
stay
open
long.
Shorter
durauion
cams (smaller
noae spread)
speeds up the
valve
and has less
duration
vhlch
HURTS R.P.M. but
helps torque
and lov
end
pouer.
The key here
is hos nuch duratlon
ls need.ed and the best settlngs
to geb thls
duratlon
glvtng
rtthout
up anythlng,
Thls
Z111ion
1e the
DoIlar
and there
vlll
always
be nore.yays
Question
than one to qet fron
Point A to Polnt B.
You can pretty
nuch put
thls
1n the
bank 3 Duration
this
is figured
Yay.
Yalve Open + Yalve Cloce + 18Oo = lotal
Duratloa.
This
can
be
figured
any where
ln
the
can proflle
to eort
out
one can from another.
More duratlon
neana nore top end porer and less
the nost parb,
neanB for
nore torgue.
place
On a Box Stock
Can the
best
to
flgure
the
Close is
Intake
chere tbe E Z Spin Bunp starts.
Okayr lettE
look at thle
thought.
Letra assune that
the E Z Spln Bunp atarts
at 45o A.B.D.C.
We have
an openlng of 30o on the Intat(e.
This rould cone out at:
I.O.
30+
If
the
E Z Spln
r.C.
45
start
I.O.
30+
Ie
+tlg=
If,TIf,B
DUII'IIOX
2250
on 6Or
r.c.
ItrTlf,B Dutltrof,
60 +l8O=
27Oo
Sone engine
bullders
say to set your
Bunp.
Thls ls
not
the faetest
say nost of
up can you donrt need to for the most part.
On the
exhaust
slde
of
the
cam re
flgure:
Erhaugt Open + Erhauat Cloae + tSOo
SAIIPLE:
B. O.
60+
B.C.
15
+180=
EIEAUSI
255
can up to clear
the
E Z Spin
the tine because you I re giving
have tt
a Total
a 1lttle
Duratlon.
easler.
To
DUIIIIOX
For
my partr
I
feel
that
total
duration
off
the
for
seat
a good
running
Box Stoclrer
needs to be fron
250o to 270o.
250o would
be
on
the
torque
slde
sith
270o being
the
top
side
and
leaning
on the
R.p.M.
side
of the horsepover
curve.
(.425
I{ith
a restrictor
motor
and
up) you don I t have any alr
so the
part
faster
Yay
for
the
most
will
be
bo glve
up
duratlon
for
torque.
Donrt
tty
to
turn
the
notor
you donrt
hard.
This
takes
alr
have.
Malce
ib torgue
and to get
top epeed to rln
rith
by taking
off.
teeth
your
If
motor
is an unre6trlcted
englne,
a
a good
number
round
for
49
place
starting
vould
be 250o bo 260o for
260o to 265o for
a heavy kart;
a
medium and naybe as bigh
as 2650 to 270o duratlon
for
a llght
class
kart
stock.
or super
point
you need to
Another
look
at
is
overlap.
Valve
valve
overlap
this
Yay! B:haust
+ fntake
is figured
elose
Openlng.
you have an exhaust
Let I s say that
of 2Ao and
an
close
intake
openlng
of 30o,
then
se $ould
have:
B. C.
20
I.O.
30
OYBBLAP
500
Anything
short
of
a Super Stock
rould
have a hard
tirne handling
thls
nuch
overlap.
porer
fn
short,
you
to
nake
vith
this
nuch
overlapr
have
to
(Or5OO R.P.M. )
turn
the
notor
hard
pover.
make
This
to
comes baclc to
carburetion.
You j ust
don I t
have
enough air
coning
through
a stoclc legal
carb
to nake nuch power here ab this
R.p.M.
Why does overlap
you?
hurt
Because
is the length
of
time
this
that
both
valves
are
precious
po$er
off
the
seat
in degrees
and neans that
ie
past
lost
by going
the open valves
the vrong
way.
I
like
a close
on the
exhaust
of 15o.
porer.
This
1s the
spot
for
around
Anythe
best
all
thing
under
13o close
ri11
nake too nuch
englne
heat
to
sult
me.
On a
Stocker
earlier
openings
guicker
of 30o help
filf
the
cyllnder
but
blov
back fron
the exhaust
into
the
carb
at
lorer
R.P.M.
hurts
the
signal
of
the
carb
and
torgue
suffers.
Longer
headers
vl11
help
offset
this
problem
soneo
Again
all
cones
back
to duration
it
and how the can 1s ground.
If
(50 to
the E Z Spin Bunp starts
get the
late
60 max) then you can sti11
quick enough for good seal
Intake
Valve
back on the seat
vithout
to early
gives you the duratlon
of an openlng.
This
shortens
the overlap
but
to
nake horsepofler.
It I s almost
lllce havlng your
cake wlth lce crean on tt,
isn't
it?
Renenber
back
anays '
vhere
I
said
the
E Z Spln
Bump nas a Tuning
get baclc to
Factor
and we nould
it.
It
starts
deep here
to get
and every
motor
is
different.
One thing
1s knovn
for
sure
and that
is as the motor
runs
during
the
race
it
heats
up.
As
it
heats
up
the
valve
tiurlng
changes
from
thls
problen
heat.
The only
here
is alL blocks
are
different
and
they
expand
dtfferently.
fn
short
and
for
gebs hot,
round
numbersr
as the block
the
exhaust
valve
side
of the block
shrinks.
Botton
lines
valve
rill
lose
clearance.
Nov
on
the
intake
fuel
Eide r
the
cold
coming
1n makes
the
grov
block
on this
side
and ve ga.in valve
lash.
Hor much your
valve
lash
changes
get.
depends
on hov hot you let
the notor
This
1s vhy
f
don't
bel leve
in 400o tenperatures
on motors.
My motors
are
set
up
on
the
tight
side
and thls
much heat
rould
change
ury valve
tlnlng
considerably.
I keep ny engines
at 325o to 350o !ldxo
Thls
is the tenperature
that
Irn
used to so f can
you have a loose
conUrol
ny
valve
tiurlng.
If
you
notor
si11
have to run a little
nore heat
1n it
to
keep
1t
sealed
up.
As you
you
nake
nore
your
heat
wi 11 have
to
set
valves
bo
offset
the
block
expans i on .
.f,ILLEB
Now yourre
starting
to see
$hy
making
BOISEPOTEf,'
OUt
Of
Box Stocker
is close
to Black
llaglc.
Back
at
the
beginning
I
stated
that
there were trro rays
to
figure
center
1ines.
The
exercises
that
Yent throughr
we just
rof,lcing .050 of f,
the nose,
is the best
vdy,
I feel r to figure
vhat
out
the
center
line
of
a given
lobe
is and this
is what you I re going to go to the race track
wi th.
you I re rondering
But if
your
1f
carn grlnder
getting
ls
tricky
vittr
you
j
u
s
t
you
and
naybe
have an asynmetrical
you
can grind,
here
is
hov
find
out.
You
figure
the
center
line
off
of
the
duration
of
the can.
50
cam and
take
our sanple
EC #327 Cam for
Again tle n111 use the
Lobe.
off
of the Exhau6t
cise
nose rve
the lobe
When ve
run
the
center
line
out over
vha-t you
Now fron
for
Lobe Center
Line.
110.75
the Exhaust
you knov that
the top
end
torard
this
center
llne
1s leading
you?
rith
band.
Or dld
I geb a 11tt1e
bricky
your
we do it
of the duration
To figure
center
line
off
the fornula
is:
E.O.
DMDEL
Okay non letIs
+
B.C.
BI
2t
put
+
180
XflfUS tbe
=
exer-
this
cone up with
have learned
of the potrer
this
uay
and
DUATIIOX
E.C.
6one nunbere
= EIETUST CBXTBI LIXB
1n rith
it.
=
+
+
B.O. 61.5
B.C. l5
256.5
180
=
256.5 DIYIDBD BI /
128.25
128.25 IIII|US B.C. of 15 = CTL 113.25 FOB TEE EIBAUSI LOBE
Looks
ir.
The 113.25
E.C.
like
center
Center Llne ls a better
torque
got trick
on you and had ice crean put
110.75.
line
than
on his calce, dontt
What's the botton
llne?
go fit
your type of racing.
lines
Pick the can wltn the center
you have at set up.
Pay close attenilon
to hor !ruch duritlon
you have.
Pay close attentlon
to the anount of overlap
it.
Pick a heat range for your notor and stay rith
c
means nore
neans nore
torgue,
More duration
Remenbers Less duration
pover
sone loss
to
end pover.
The sane holds
true
on top
rlth
loc
vith
overlap.
Bump you have shorlng
vlll
rhat
true
control
the
6) Hou nuch E Z Spin
the
intalre valve ri 11 be .
In
short,
let I s assune that
a
clos lng
of
gror
block
rill
.006 on
the
motor tenperature
of 3500 that
the
I
2
3
4
intake
side.
Thls
vould
take
an
I . O.
of
2Oo and
a
close
of
the
j ust
short r
lntake
duratlon
has
drobped
valve at 25o .
In
intake
duration.
Botton
11ne agaln:
not
enough intatie
valve
to 225o total
timing
to nake very nuch pover.
of the
bloc)c
side of f he block gross 1 the
exhaust
side
7') As the lntake
g
o
i
n
g
o
u
t
.
due to the heat
shrinks
have at
least
.004 clearance
on the
exhaust
8) This
neans you better
Thie
vould
also
change your
valve
or
it
nay not seal up chen hot.
on this
valve by as much as 10o to l50.
valve duratlon
Make changes of 20 only
9) Keep very close recordE on your can setting.
t
r
a
c
k
and test
on race
for
best overall
times.
Resrenber
at
a bine
back at the startr
20 can mean nany feet
of valve
and piston
travel
in one heat race or feature
race.
llnes
or Open bhe above steps and lnformablon
on center
On a Llnited
on your motor.
duration
and heat have the sane effects
overlap,
can
difference
here ls you have moFe to sork rith.
The only
Porting
and ve noy have 'State
be rilder
for
nore
flov
of
TllIotBon
the Art'
to supply the needed air to feed your engine.
Carburetors
your duration
or 0pen you vant to figure
off
the
seat
On a Limited
p
l
a
y
power.
running
11ft.
They both
a key part in horseand at.050
for torque r.ould be 290o to 295o.
the seat duratlon
off
Mid Range vould be 2950 to 300o.
Top end 300o to 315o
.
At .050 llft:
Torque at 238o to 2430.
Mid Range at 2430 to 2480
Top end at 250o to 260o.
51
No, a
unless
Super stock,
Limited
or Open does not run its
best
at 4O0o plus
it's
ki1ler
1oose.
A11
tbe fast
boys
will
keep
their
motors
round,
tigh!
and
sealed
up.
Motor
tenpr
they
will
hold
at
ZAOo to 325o.
'Iust
remember,
when you see snoke coning
out
of your
catch
can anal a
heavy
dose
of
oi1,
this
means
your
horsepower
is going
in there
with
it
also.
The
best
tools
you
can own for
Stockers,
Linit,eds
or
opens
donrt
cost
a fortune.
No it's
not
a Dyno or a Flors Bench.
Itrs
a $1.00
note
pad for
records,
a leak
down tester
and one herl
of a lot
of r.L.c.
products
E.C.
Racing
von I t hurt
you either.
WISECO''SUPERSTOCK''FORGEDPISTONS
:,'i","il?l'?:t'*fo
'ff"q{I,'tffi
l*;':?:,*Hxldepend
. Pistonsaresoldwithoutrings,circlips& wristpins
1.190''
HEIGHT
COMPRESSION
1993PS 2.5625STD.
.005
1993P0s 2,s57s
1993P1 2.5725.010
1993P.|
5
2,5775.015
1993P2 2.5825.020
.025
1993P25 2.5875
1993P3 2.592s.030
Super
Slock
Forged
Pislon
85298982 83298909 03s.21
85298983
8S298983
85298984
85298984
8S29898s
8329898s
HI PERFORMANCE
PRODUCTS
FORBRIGGS& STRATTON
5 H.P.ENGINE
HIG HS T R EN GT HB IL L E TR OD S
Horstmanhighperformance
rodsare CNC machinedkom billet7075T6 alloyalumrnumTheyare vrbrahoned
and shotpeenedto eliminate
unwantedstr€ssinducingtoolmarks.H beammodelsareprovento bs
th€ most relrablerods available.HorstmanI beammodelsteaturea
-drrlled
cenler"torweightsavrngwrihoutsacrificing
strength.Thissaves
engrneburlders
manyhoursof painstakrng
laborto removeweightfrom
the rod
H gEarr,t
P A R TN O .
4HRB-5
4 H R8 . 9
4 H R B .O
l S
4HRB-175
4 H RB - 3 2 5
4HRB-375
4HR8-425
4HRB-475
4HRB-500
RACER
NET
48.75
56.25
56.25
5 6 . 25
56.25
JO.ZJ
f,o.zJ
CENTERTO CENTER
DISTANCE
J
I BEAM
PARTNO.
RACER
NET
6/3
4 000'
4 175"
4 325"
4 375"
4 425"
5 6 . 25
A
JO.ZJ
4 500"
AAF"
52
71.25
71.25
71.25
71.25
I
EC's
TEST
BENCH
PRO.TEC
The Way To
Cheat Legally
Lite in the last lane is not an easy one.
Sincethe beginningol time there has
alwaysbeen thosewho run up front and
thosewho run from there on back.
To run up front you have to do two
things;build the best racingsquipmont
Wm^
lIDl
?s3
you know now lo and drive your h€arl out.
One edge you can have on the other guy
is to got rid of the friction in your racer.
Friction is the biggest robber ol power and
the tuner thal knows how lo combat this
horsepowerrobber is the one that will go
fasl€r and run longer than anyono else.
Now wouldn'tit bs n€at lo know how
to knock off anywhgr€trom I to I tonths
on your lap time and pick up a 10 porcant
horsepowergain? lf you like this ideath€n
read on, exil right, stage left whore the
winnersare,
Pro-Tecis a new spaca age antitriction metal treatmentthat is a petrol€um
based producl tormulatedfor uso rrith any
p€troleum,minoral,or synthoticlubricant.
Pro-TecAnti-FrictionMetal Treatmonl
claimsto be unlikeother oil additives
becauseit treats th€ metal itself. In short it
is not an oil additive.But you do put it in
your oil so that it can get a free ride to
overypart of th€ engine,bearingor
whatever.
What does Pro-Tecdo? As th€ name
indicates,Pro-TecAnti Friction Metal
Treatmsntactually troats th€ metal surlace where sver it is used. lt claims to
s€al and coat th€ melal surlac€s in an
engine.lrangmission,rear end, wheel
boaring,powersteeringunit or air conditioner comprgssor.In short, wherever
metal moves against metal Pro-Teccan
be used. How much ot this wondor stuff
do you hav€ to use? Well, lor th€ most
part a ratio of 2 ouncas to one qt. of oil or
one lb. ot greaseis enough.ll you're in a
hurry and want to get all the gains possible in half the time us€ 4 ouncesto one
qt. of oil.
Pro.Toc and Four'Cyclc Baclng
For the last year and a halt I have
been racing four-cyclekarts. In the very
beginningI noticedcylinderwall scuffing.
Buildingthe motorsloosedidn't solvethe
probl€m.All that did for me was drop
cylinderpressureand cul down on torque.
Ring wear was driving mo crazy. Pro-Tec
pul a stop to oxtensivgwear. What really
sold me was what happenedlast week.
Dummyme, I drainedthe oil out of one of
my engin€s,(Yes I did it, too),you know
iho rost ol the story;but I'm going to tell it
anyway.
The phonerang and by the time I got
bEckto my engino, I had torgottenthat I
had drained, but nol r€placedthe oil in my
very best engine.I had just put a
Magnetronon to do some resoarchon timing. I put this engineon the onginestand
and started running the be-iezzesout ot il.
Aftsr stopping end starting it 5 or 6 tim€s
it finallydawnedon mo that I had not put
oil back in tho motor!Needlosslo say I
about had a coronaryand with a quick
yank ot the plug lead, I shut the motorott.
I knew lhat th6 best thing at th6 momont
was to get som€ oil in it while it was still
hot. I poured in oil (WithPro-Tec)and
boforeI let it start,I pulledit througha
dozentimgs,and then fired tho motor.
Wh6n the motor lired I rowed it up lo
5,000R.P.M.and held it there for abouts
seconds.Afterthat I just rewed it up and
down the scale for a while.I l6t it run tof 3
or 4 minulesthen shut it off. Now I had to
mak€ a dgcisionon whetherto open it up
and look lor damageor torgetit for the
tim€ being.I had only one hour left to get
it back onto the kart and to the 'Barn' for
an indoorrace that evening.
Since I had used Pro-Tecin the oil
before.I made thg decision,based on
tests I'd seen (Pro-Teccan stand over
400,000lbs. of pressurebeforegalling)to
iust go on lo lhe races.Not only did the
kart run flawlessly,it won. YesterdayI
pulledthe enginedown to the last bolt and
nut. Nowhorein it was lhere a trace of the
engineover runningwithoutoil. The valve
guidesare still perfect,.0005clearanceon
the rod. Therewas no sign of pistonor
cylinderwall scoringeither.I'm not lelling
you lo drain the oil out ol your engineand
run il, but if you do a dumb, dumb trick
like I did wouldyour motorturn out the
same \^raywith no damage?
2-Cycle Engines:
T€stingPro-Tecin 2-cycletuel made
ms a littlo nervous,but the man that goes
the tastestis the one that gamblesa little.
I discoveredthat when I mix a ratioof 2
oz. of Pro-Tecin a gallonof Pre Mix, that I
can take that fuel, put it in the test
machinoand pull upwardto 250,000lbs.
ol pressurebelore I galledthe tester.
Now, the way I see it this meansthat
enginetemp. can climb higherthan ever,
beforeI make a one piece part out of my
engine.Now there is a kickerhere and
thal is that Pro-Tecwill not blendwith all
oils.There are some oils in the vegetable
familyit doesn't like. so if in doubt,send a
sampleot your oil to a Pro-Tecdistribulor
and they will test it tor you
PRO.TECGREASE:
Pro-Techas recently introduceda new
white groase.This is an overkillgrease
with tho trick stuff in it. water doesn'tget
to it and il will bl€nd with oil which makes
tor a very good pre lube when puttingan
enginetogether.
PRO.TECXL.24OPENETRANTSPRAY:
XL-240is also a new Pro-Tecoroduct.
From what testingI've done, at the moment this looks like it might be the best
thing since pop-cornand candy.Chains
will lov6 XL-240.The XL-240will get down
insidethe chain and when the carriergoes
away th6 metal is protectedcompletely.
The XL-240will also work as an engine
assembl€lubricantalong with the grease.
The hot tip here is to spraythe part first,
then put th€ greaseon top ot it, (insid6ot
your molor and in your wheel bearings).
Sprayyour rear wheel bearingsanctit will
penetrateright into the melal.
Thereare still thingsthat I don't know
about Pro-Tec.The peoplethat make it
don't even know all the answers.In tact,
they may neverreallyknow how good this
wonderlube is. One thing I do know is
this; if you want to run tasterand longer,
then Pro-Teccan and will help you do it.
My25plusyrs Experience
is cheaper
thanyourMistakes.
f 309 Old Charlotte Pk.,Dickson,Tn.3705s. Pf{.615. 116-6t07
CoFrientg
is
The following
Racing
Mc Duffie
l.r{
|r.2{
1,.,,i.,, 1,..,
is
a copy of
/pter^
f-esu //s
3.o!
//oo
_a
run
ev""
.33
Sanford,
| r.3
Fan h*4
/bs .
L.24
1981;;
a Dynamometer Test
Racing Team, March 11,
co'nenrB G*rr> e/
Mc Duffie
The following
de r. , ,
8.37
by J.D.
N'C.
4,
| r.lr
1 3 0 9 O f d C h a r l o t t e P k . , D i c k s o n ,T n . 3 7 0 5 5 . P l { . 6 1 5 - 4 4 6 - 6 t O 7
M y 2 5 p l u sy r s . E x p e r i e n c ies c h e a p e tr h a ny o u r M i s t a k e s .
EDGE!
THEGI|MPETITIUE
r.3
a copy of a Dynamometer TesE run by J.D
Tearn, March 1 1 , f 9 8 f ; ; S a n f o r d , N . C .
Almost Everything You Wantedto
Know About Tillotson Carburetors
olillofson, @.9.4\.
Storyand Photosby E.C.Birt
HL and HR
CARBURETORS
T i l l o t s o nL t d . i s o n e o f t h e o l d e s tm a n u f a c t u r e r si f. n o t t h e
o l d e s to, f s m a l le n g i n ec a r b u r e t o r si n t h e w o r l d .T h e i r b e g i n n i n gg o e sb a c k t o t h e e a r l y 1 9 0 0 ' s .
I n t h e i n f a n c yo f t h e b u d d i n ga u t o m o t i v ei n d u s t r y ,a c o m p a n yi n T o l e d o , O h i o i n 1 9 1 4 w a s f o r m e d c a l l e d T i l l o t s o n
ManufacturinT
g .h e i rf i r s tb i g s p l a s hi n t h e f i e l do f c a r b u r e t i o n
w a st o d e v e l o pa f l o a t b o w l c a r b u r e t o rf o r a n " o v e r l a n d "v e h i cle now known as "Jeep".
I nt h ee a r l y1 9 4 0 ' st h e s m a l le n g i n em a r k e t sw e r eb e g i n n i n g
t oe x p a n dB
. y t h e e n d o f t h e 4 0 ' s ,m o t o r sw e r eb e i n gd e s i g n e d
that operated in positions other than vertical. This type of
e n g i n em a d et h e d e m a n df o r a c a r b u r e t o rt h a t w o u l d o p e r a t e
i n a n y p o s i t i o n .T h i s d e m a n d l e d t o t h e d e v e l o p m e n ot f t h e
T i l l o t s o nD i a p h r a g mC a r b u r e t o rM
. r . B . C .P h i l l i p st,h e n C h i e f
E n g i n e eor f T i l l o t s o nM a n u f a c t u r i n go,b t a i n e do v e r 3 0p a t e n t s
o n t h i s D r o d u c tl i n e a l o n e .
B o t t o mL i n e :l f y o u d o s o m e t h i n gs t u p i da n d o v e rd r i v et h e
f i r s tt u r n a n d f i n d y o u r s e l fo n y o u r h e a dg o i n g d o w n t h e b a c k
s t r a i g h t - a w a yt h, e m o t o r w o n ' t s t o p r u n n i n gt i l l t h e g a s t a n k
f a l l so u t .
T i l l o t s o nh a s a l w a y sh a d a n i n t e r e s ti n r a c i n ge n g i n e sa n d
t h e i rc a r b u r e t o rn e e d s .I n t h e p a s ty e a r sI h a v eb e e nw o r k i n g
v e r yc l o s ew i t h T i l l o t s o ni n t h i s f i e l d .M o t o rt e c h n o l o g yi n t h e
2 - C y c l ea n d 4 - C y c l ec l a s s e sh a v eu n d e r g o n em a j o rc h a n g e s .
T h e s ee n g i n ec h a n g e sh a v ed i c t a t e dt h e n e e d sf o r c a r b u r e t i o n
t h a t c a n h a n d l et h e n e w e r e n g i n e d e m a n d sn o m a t t e rw h a t
t y p e o t r a c i n g f r o m k a r t i n g ,q u a r t e r m i d g e t s ,w a t e r c r a f t t o
. o h e l pa s s u r et h a t t h e r a c e rg e t sw h a t h e n e e d s ,
r a c ep l a n e sT
w e h a v es e t u p a R a c i n g R & D C e n t e r h e r e t o d e v e l o pt h e
n e e d e dc a r b u r e t i o na n d f u e l s y s t e m sf o r r a c i n ga p p l i c a t i o n s .
W i t ht h e f e e d b a c k f r o m t h e e n t r y l e v e lr a c e r st o t h e p r o s ,a
s p e c i atl h a n k st o y o u f r o m m y s e l fa n d T i l l o t s o nL t d . f o r y o u r
i n p u t .Y o u h a v e p l a y e da b i g p a r t i n t h e d e v e l o p m e not f t h e
c a r b u r e t i onne e d e df o r t o d a ya n dt o m m o r r o w ' sr a c i n ge n g i n e s .
55
What's new? Well, if everythinggoes as planned, by Dayt o n a t i m e I w i l l h a v e a 2 4 m m ( . 9 4 5 )V e n t u r i T i l l o t s o ns l i d e
carburetor for the Open 2-Cycle and 4-Cycle engines.And
y o u t h o u g h tt h a t H u r r i c a n eA n d r e wh a d s o m e t h i n gg o i n g f o r
h i m i n a i r f l o w .W a i tt i l l y o u s e et h i s h u f f e r .T h i s o n e i s f o r t h o s e
o f y o u o r a n y o n et h a t t h i n k sb i g g e ri s b e t t e r .J u s t b r e a ko u t o f
y o u r b o r i n gb a r a n d h a v ea b a l l .
H L - 3 6 0 A : T h i iss a n o l f s p r i n go f t h e H L - 3 5 5 Af o r a t k ym o t o r s
b u t s e t u p w i t h a d r i l l p a t t e r nf o r g a s . P e r f e c tf o r t h e 2 - C y c l e
c l a s s e st h a t h a v e a S t o c k A p p e a r i n gC l a s st h a t r u n o n g a s .
Y e s ,t h e C o m m e r M o t o r sw i l l f a l l i n l i n e w i t h t h i s c a r b .A l s o ,
t h i s i s t h e a n s w e rf o r t h e 2 - C y c l ed i r e c t d r i v e c l a s s e so f t h e
e n g i n eb u i l d e rt h a t n e e d sa b i g H L s e r i e sc a r bf o r a s p e c i a dl r i l l
patternthat he likes to do his way.
H L - 3 4 8 B :W i t h t h e f a s t g r o w t h o f t h e B r i g g s S u p e r S t o c k
C l a s st h e H L - 3 4 8 Aw a s j u s t a t o u c h o n t h e r i c h s i d e f o r t h e
entry level racer new to Tillotson carburetors.To cure this
p r o b l e m ,I t i g h t e n e du p t h e d r i l l p a t t e r ni n t h e c a r b a n d h a v ea
n e w a c c e s s o r yh i g hs i d en e e d l ef o r i t .T h e s ec a r b sa r e i n s t o c k
a t l e a d i n gT i l l o t s o nd e a l e r sn o w .
L a s t ,b u t n o t l e a s t ,i s t h e a l l n e w H R - 1 9 1T i l l o t s o nf o r t h e
2-Cyclecontrol classes.This all new Tillotsoncarburetorwas
d e s i g n e da n d b u i l t t o f i t t h e n e e d so f t o d a y s" s t a t e - o f - t h a
ert"
e n g i n e s .l t i s " u s e rf r i e n d l y "f o r t h e e n t r y l e v e lr a c e ra n d w i t h
t h e p e r f o r m a n c et h a t t h e p r o r a c e rd e m a n d s .
T i l l o t s o ne a r n e dt h e r e p u t a t i o nm a n y , m a n y y e a r sa g o o f
b e i n gu s e rf r i e n d l yT. h e H B - 1 9 1l i k et h e H R - 1 8 1w i l l k e e pt h e
f u n i n r a c i n g .W i t he i t h e ro f t h e s ec a r b sy o u d o n ' th a v et o l e a r n
h o w t o d r i v ew i t h o n e h a n d o n t h e s t e e r i n gw h e e la n d o n e i n
t h e c a r b u r e t o rT. h e H R - 1 9 1w i l l b e l e g a li n t h e l . K . F .c l a s s e s
f o r 1 9 9 3 .W . K . A .h a s o u t a h o l d o n i t u n t i l 1 9 9 4 .
N o w l e t ' sl o o ka t t h e n u ta n d b o l ts i d eo f a T i l l o t s o nc a r b u r e t o r .S o m eo f t h e " t r i xo f t h e b l u e p r i n t e r sa"n d h o wy o u c a nc u t
s o m e r a c t n gc o s t s .
KARTERNEI,VS/ JANUARY 1993
T h e t e r m b l u e p r i n ti s s o m e t i m e sv e r ym i s l e a d i n gW
. h e ny o u
b l u e p r i n ts o m e t h i n gi t c a n f a l l i n t o a s m a n y s t e p s a s t h e
k n o w l e d g eo f t h e G u r u t h a t i s d o i n g t h e w o r k .W h a t I ' m g o i n g
to attemptto teach you is what it takesto set a Tillotsonup to
f i t y o u r g i v e nn e e d so f r a c i n ga n d s t i l ls t a yi n t h e g u i d e l i n e so f
l . K . F .a n d W . K . A .t e c h .T h e f o l l o w i n gt e c h n i c a ls t e p s ,p r o c e d u r e sa n d o p e r a t i o n sa r e p r i m a r i l yf o r t h e 2 - c y c l er a c e r .
T h e T i l l o t s o nn e e d sf o r t h e 4 - c y c l ec l a s s e si s a w h o l ed i f l e r e n t b a l lg a m ea n d w i l l t a k ea n o t h e ra r t i c l eb y i t s e l f o r y o u . B u t
d o r e a do n . A l o t o f t h e f o l l o w i n gi n f o r m a t i o nw i l l s p l a s ho v e r
i n t o y o u r r a c i n gm o d e .
T h e r ei s n o t h i n gq u i t e s o s i m p l ea n d a t t h e s a m et i m e m o r e
c o m p l i c a t e dt h a n a c a r b u r e t o r .M r . W e b s t e r t, h e o l d g e n t l e m a nw h o n e v e rs a wa k a r ti n h i s l i f e ,s u m m e di t u p t h i sw a y a n d
t o o k t h e e a s yw a y o u t . H e s t a t e dt h a ta c a r b u r e t o ri s m e r e l y" a
d e v i c ef o r m i x i n gf u e lw i t h a i r . "B u t i f y o u h a v ej u s tc o m eo u t o f
the world of box stock 4-cycle racing and stepped into the
r u s h i n gw o r l d o f 2 - c y c l er a c i n g ,y o u h a v es o m e s c h o o lt i m e
c o m i n g . T h a t s t r a n g et h i n g s t i c k i n g o f f t h e f r o n t o f y o u r
e n g i n e w i t h t w o ( 2 ) n e e d l e ss t i c k i n go u t t o f i d d l e w i t h a n d
e n o u g hp a r t si n s i d et o f i l l u p b o t h h a l v e so f a B u r g e rK i n gb o x ,
i s t h e b e g i n n i n go f a r i d e i n t o t h e T w i l i g h tZ o n e .
B u t ,h a v en o f e a r ,I w i l l g e t y o u t h r u t h i s .T h e nf o r a f o l l o wu p
act l'll walk on water and top it olf by staying under for 30
minutes.
E X I TR I G H T : S T A G E
LEFT.
Before you can lix or set up any mechanicaldevice, you
n e e dt o h a v ea n u n d e r s t a n d i n g
o f h o w i t w o r k s .T h e T i l l o t s o n
carburetors used on 2-cycle racing engines fall into two (2)
g r o u p s .1 ) S i n g l ep u m p s t a c ku n i t sw h i c hf o r t h e m o s tp a r t ,t h e
HL series carbs used on Control Rotaries,US-820,Comer,
TS-40and whatevermotor that doesn'tdemanda high volume
o f f u e l s u p p l y . 2 ) D o u b l e s t a c k p u m p s .T h i s p u m p s t a c k i s
u s e do n t h e H R - 1 8 1 H
, R - 1 8 4a n d t h e H R - 1 9 1o r a n y T i l l o t s o n
carb to double the fuel demandsfor the engine'sneeds.Yes,
this means you can take this pump stack and fit it to any HL
s e r i e sc a r b u r e t o ra n d w i t h t h e r i g h t c h a n g e st o t h e d r i l l p a t tern, converl it over to run on funny fuel or Methanol.
T i l l o t s o n ' sl i n e u p o f c a r b u r e t o r su s e df o r r a c i n g .H L s e r i e s
which is the smallbody carb.Startingwith a venturiof .500and
' goes
up to .945.The HR series is used on the Control Reed
e n g i n e sa n d R o t a r y 1 3 5 c c E n g i n e s .V e n t u r is i z e o n t h e H R
s e r i e ss t a r t sa t 1 . 0 9 3a n d t o p s o u t a t 1 . 2 8 1 .
F o r k a r t i n g ,t h e l e g a l c a r b s a r e t h e H R - 1 8 1 ,H R - 1 8 4a n d
H R - 1 9 1. T h e b i g g e rV e n t u r is e r i e sc a r b sc a n o n l y b e u s e d i n
the Unlimitedclassesand Outlaw Stock Appearingclasses.
Yes,there is a Big Daddy Huffer.This seriesis the HD line
w i t h a 1 . 5 0 0v e n t u r ia n d a 1 . 6 2 5t h r o t t l ev a l v e T
. h e H D S e r i e si s
in the proto stagesfor mini sprints and water craft.
The basic requirementfor any carburetor is that it meters
t h e f u e la n d a i r i n s u c hp r o p o r t i o n sa s t o b e e a s i l yc o m b u s t i b l e
and enable the engine to produce good power over a wide
R P Mb a n d .
The first feat of walking on water is controlled by us at
Tillotsonin the selectionof partsto manufacturethe carburetor out of . The next problemwe face is putting in a drill pattern
f o r t h e l o w s i d e c i r c u i tf o r t h e f u e l d i s c h a r g ep o r t s t o t h e a i r
streamthat linds its way to the motor.This part of the carburet o r ' sl u n c t i o ni s c o n t r o l l e db y t h e l o w s i d en e e d l e O
. nthehigh
side,we haveone (1) dischargenozzleand its f uel deliveryinto
the air streamis controlledby the high side needle.To assure
us that this signal is great enough to supply the engine's
demandsfor fuel in the HR series,there is what we call a bulls
eye casted into the top of the carb that the high side nozzle
s t i c k st h r u . I n s h o r t , t h e h i g h s i d e n o z z l eh a s i t ' s o w n l i t t l e
v e n t u r it o s p e e du p t h e a i r a n d i n c r e a s et h e v a c u u ms i g n a lt o
p u l l t h ef u e l i n t ot h e a i r s t r e a mT
. h i sw a y a r i c he n o u g hm i x t u r e
of fuel will find its way into the motor keepingif from seizing
a n d t u r n i n gi n t o a o n e p i e c eu n l t .
Due to manufacturingtolerancesand your personalneeds
t o f i t y o u r r a c i n g t, h e r ea r ec e r t a i ns t e p st h a t y o u c a nt a k ea n d
changesto be made to fine tune your mixer to a razor sharp
JANUARY
1993/ KARTER
NEWS
e d g e .T h i s i s w h a t w e c a l l b l u e p r i n t i n g .
N o w I ' m g o i n g t o t r y a n d s e ei f I c a n t e a c hy o u t o s t a yu n d e r
w a t e rf o r 3 0 m i n u t e sa n d t h e n c o m e u p .
Beforeyou do any stepstoward blueprinting,thereare a few
toolsthat you will need.Someof them you can makeand some
y o u w i l l h a v et o p u r c h a s ef r o m o n e o f t h e k a r t s h o p s i n t h e
know. For sure you haveto have a pop-off gauge.Without it,
f r o m h e r eo n o u t , w i l l b e l i k et r y i n g t o p l a y b a s e b a lw
l i t h o u ta
b a t .R e f e rt o t h e p i c t u r e sf o r w h a tt h e t o o l sy o u n e e dl o o k l i k e .
O . K .L e t ' sh e a do u t t o t h e s h o p o r b e t t e r y e t ,i f t h e l a d y o ft h e
h o u s ew i l l l e ty o u , b r i n gy o u r c a r ba n d t o o l si n t ot h e h o u s ea n d
set up at the kitchentable.The lightsare better,the f rig is close
by and it saveswalkingsteps.You haveplentyol hot waterand
t h e d i s h w a s h ew
r o r k s p e r f e c tf o r c l e a n i n gp a r t sa n d y o u r K &
N filter.
The first step in blueprintingis to get all of last weeks race
track scrubbed off the outside of your mixer. Now go to the
cabinetand get yoursella bowl that'sabout 3 times largerthan
y o u r c a r b .Y o u n e e dl o t so f r o o m b e c a u s ei t m a k e sf i n d i n gt h e
parts easier when you need them. Now comes the fun part.
Hereyour favoriteracer,son or daughtercan help. Everything
that will come out or off of you carb, do it.
When the time comes for your carb to go back togetherand
you find that you havewound up with extra parts,don't throw
them away.They havea need in the life of your mixer and will
f i t s o m e w h e r e l.' v eg o t t o g o m a k ea p i t s t o p a n d g e t a c u p o f
coffee. By the time I get back you should have a bowl full of
parts.
I'm back. Scratch around in your bowl of parts and find the
f uel cap. Look at it real close and see if there are any cracksin
i t . l f n o t ,t h e n t a k e a s h a r p k n i f ea n d e n l a r g et h e u n d e r s i d eo f
t h e h o l ej u s t a t o u c h . ( l u s ea c a r b i d eb a l l c u t t e rf o r t h i s s t e p . )
This will helpthe fuel flow into the top of the carbfuelwell.
A l s o ,i t ' sa g o o d i d e at o r u n a . 1 4 0d r i l l b i t t h r u t h e s t e mo f t h e
fuel cap to open it up just a touch for more fuel flow.
Now find the cork and the screen that was under the cap.
T h e c o r k y o u c a n f i l e i n t o F i l e 1 3 .T h e s c r e e ny o u c a n c l e a n
with a toothbrush and hot soapy water. The screen in your
carb is probably a silver screen in color. The part number of
this screenis 95-'l70 and is a very f ine mesh.When clean it will
passenoughf uel for a gas molor and f ilter out very smalltrash
which will find its way into the needleand seat,causingyou a
b a t c h o f p r o b l e m s .O n e t h i n g t h a t w i l l g e t t h i s s c r e e n i n t o
t r o u b l e i s d i r t y f u e l a n d d i r t y f u e l i s a m a n - m a d ep r o b l e m .
(Eitherthe local gas station or you.)
To ward off this problemthere are a few easystepsthat you
c a n d o . F i r s t ,I w o u l d n ' tt h i n k a b o u ts t a r t i n gt h b m o t o rw i t h o u t
h a v i n ga n i n - l i n ef u e l f i l t e ri n t h e f u e l l i n e .F o r a f u e l f i l t e rI l i k e
the Walbro f ilter, part number is 125-512.Beware!!There are
some copies on the market that don't do as good a job of
cleaningand cost just as much as the geniuneWalbro In-Line
Filter.Do yourselfa favor and don't cut corners here.
T h e r ei s o n e n o - n ot h a t I s e ea l l t h e t i m e . N e v e rs t r a i ny o u r
fuel thru a paint strainer or a coffee filter. These filters are
made out of some kind of materialthat the fuel will wash out a
fine lint that will go into the fuel and find its way to the fuel
s c r e e np l u g g i n gi t u p . B o t t o m l i n e . Y o u r b e l l y c a n s t a n dt h i s
problem, but your carb can'l. The best filter you can use is a
ladies nylon sock or the leg off an old pair of panty hose
s t r e t c h e do v e rt h e t o p o f y o u r f u e l f u n n e l .T h i s w i l l c a t c h a n y
foreign objects in the fuel and keep your fuel blend lint free.
Another NO-NO. Don't be putting zip ties on the fuel lines
wherethey go onto the tank,fuel filtersor cap to the carb.This
can causean air leak into the f uel systemthat can developinto
a tuning problem that will drive you up a wall.Just replacethe
fuel lines and don't let them get hard. They won't come off. ll
y o u ' r ep a r a n o i da b o u ta f u e l l i n ec o m i n go f f, t h e nd o a m i l i t a r y
tie-off with a safety wire. (Double wrap before you twist it
together.)This way you havea perfectseal.
Now, let'sturn our attentionto the fuel pump plates.With a
brassbrush and hot soapy water,scrub them good and get all
of the old gasket traces off. After you have completed this
56
o p e r a t i o nt a k ey o u r s u r f a c ep l a t ea n d 4 0 0w e t / d r ys a n d p a p e r
(wetwith water or WD-40)and surlacethe pu mp platesu rface
f l a t . W h i l e y o u a r e i n t h i s s u r f a c i n gm o d e , t a k e t h e l o w e r
d e m a n dd i a p h r a g mp l a t ea n d s u r f a c ei t f l a t a l s o .N e x t l o o k a t
t h e l o w e rd e m a n dd i a p h r a g mp l a t ea n d t h e t w o ( 2 ) h o l e s ,o n e
o v e rt h e p u l s eh o l e i n t h e c a r b a n d t h e o n e t h a t l e e d st h e f u e l
trackin the carb body. Thesetwo (2) holesmay havea traceof
c a s t i n ge d g e si n t h e m .l f t h e y d o , t a k ea s m a l ln e e d l en o s ef i l e
and gently file out these edges for better fuel and pulse flow.
N o ww i t h t h e s es t e p sd o n e ,w a s ht h e m u p a n d p u t t h e m i n t h e
c l e a no i l e .
N e x tw e t u r n o u r a t t e n t i o nt o t h e c a r b b o d y i t s e l .f T h i s i s a s
g o o da t i m e a s a n y t o r e m o v et h e l o w s i d e f u e l w e l l s o f t p l u g .
T h i so p e r a t i o ni s a b i t l i k e p l a y i n gw i t h a c o b r a .Y o u c a n g e t
s n a k eb i t h e r e .T h i s o p e r a t i o ni s b e s td o n e i n a n e n d m i l l a n d
u s ea 3 / 1 6 f l a t b o t t o m m i l l t o c u t j u s t t h r u t h e s o f t p l u g .A n y t h i n gp a s tj u s t b r e a k i n gt h r u t h e s o f t p l u g w i l l b e a h o l ed r i l l e d
right on thru into the carb. Now all you would have left is a
p i e c eo f r e c l a i m e da l u m i n u m .N o t e v e r y o n eh a s t h e l u x u r yo f
havinga Bridgeportto use. lf you lall into this group and have
t o d o w i t h w h a t y o u h a v e ,t h e n t a k e a y s i n c h d r i l l b i t a n d
r e g r i n da 1 0 " a n g l eo n t h e e n d o f i t . N o w t a k e a c e n t e rp u n c h
a n dp u n c ha s m a l ls t a r t i n gh o l e i n t h e m i d d l eo f t h e s o f t p l u g .
W i t ha d r i l l p r e s so r a h a n d d r i l l ,y o u c a n d r i l l a h o l e j u s t t h r u
t h es o f t p l u g a n d n o t h i t t h e b o t t o mo f t h e f u e l w e l l .O n c e y o u
h a v ea h o l et h r u t h e p l u g ,w i t h a s m a l ls c r e wd r i v e ro r a w l ,p o p
t h ep l u g o u t .
O n c et h e i n s i d eo f t h e w e l l i s e x p o s e dy o u c a n m a k es u r e
that there is no collected trash in there. Sometimesyou can
m a k es m a l lc h a n g e st o t h e d r i l l p a t t e r nt o f i n et u n et h e c a r bl o r
yourneeds.But, due to the fact that this is a tech item on some
carbs,this operationis best left up to someonethat has lots of
experiencein this f ield.Bottom line!We at Tillotsonhavedone
our homeworkhere and its best you leavethis area alone. In
short,don't try to reinventthe wheel.
O n e( 1 ) p l a c e ,n o t w o ( 2 )t h a t n e e da d r i l l p u t t o i t i s t h e p u l s e
holein the carb. This hole is how the fuel pump gets ils
pressuresignal to pump up fuel from the tank. Again this
operationis best done with a Bridgeport Mill. The problem
facedthere is Tillotson had to put this hole in a certainspot in
thecarb body. When the engine manufacturermakesthe reed
orthecarb adaptors,he sometimesmissesthe hole in the carb
just a touch. In the carb itself, there is for the most part,
enoughroom to move the hole a touch one way or the other.
Thef irst step is to bolt the reedto the carb. Now put the carb
in the mill vise to hold it. Be sure that you put somethingsoft
on the side of the vise that the carb locatingpins for the pump
platefaceto squeezeinto. (l use old checkbookcoversforthis
p a d d i n g .W
) ith a long flutemill,pick up the holein the reed
valveand cut the reedand the carb in the sameoperation.For
HL Seriescarburetorsuse a % inch end mill for this operation
and HR Seriesuse a 9/64 mill.
On some ol the rotary motors and motors that havea carb
adaptoryou first haveto drill the carb out. Then make a pin to
fit in this new bigger hole to transferthe spot to the blind side
of thecarb adaptor,to know whereto movethe hole f or perfect
a l i g n m e n tB
. o t t o m l i n e h e r e i s n o m a t t e rh o w y o u g e t f r o m
p o i n tA t o p o i n t B i s a l l r i g h t ,j u s t a s l o n g a s w h e ny o u g e t d o n e
the holesall the way f rom the carb to the pressureside of the
motorare in line with each other. Alter all the metalpartshave
had the holes matched up to each other, check the gaskets
and make sure that they don't hang over into the holes.
With the US-820and the Dap TS-40,removethe choke and
choke lever. You can plug the holes with silicone. Here we
preterto turn and make pressfit alloy pins to go in theseholes.
Then set the carb up in a lathe and machinethe air inlet side
o u ts o t h a tt h e a i r f l o w w o n ' t b e h u r t w i t h a n y d e p r e s s i o ni n t h e
s i d eo f t h e c a r b sa i r h o r n .T h e r ea r e a l o t o f d i f f e r e n t y p e so f
filter adaptorson the market,but I prefer GEM's center hole
billet machinedadaptor for the HL Seriescarbs and it's legal
l o r l . K . F .a n d W . K . A .
Let'sturn our attentionnow to the needleand seat.Oh, you
s a y t h a t ' so n e l i t t l ew i d g e tt h a t y o u h a v e n ' tf i g u r e do u t h o w t o
g e t o u t y e t b e c a u s ey, o u d o n ' t h a v ea s o c k e tt h a t w i l l f i t d o w n
i n t h e h o l e .W e l l t h e y a r e h a r d t o f i n d . A t o n e t i m e , S n a p - O n
T o o l s m a d ea t h i n w a l l s o c k e tt h a t w o u l d f i t i n t h e r e .W e h a v e
t h e s es o c k e t sm a d et h a t h a v et h e O . D .t u r n e dd o w n o n t h e m .
. h e s et o o l so r w h a t L o o ka t t h e T i l l o t s o nS e r v i c et o o l p i c t u r e T
ever you need can be purchasedat the better kart shops.
O n c ey o u g e t t h e s e a to u t t h e r ei s a l i t t l ec o p p e rf l a t w a s h e r
i n t h e b o t t o mo l t h e c a r b . R e m o v et h i s w a s h e r .N o w w i t h t h e
s e a to u t y o u h a v ea d e c i s i o nt o m a k e .l f t h e c a r b i s o n e o f t h e
o l d e r m o d e l si t m a y h a v e a b l a c k r u b b e r s e a t t i p i n i t . l f t h e
n e e d l ei s s t i l li n g o o d s h a p ea n d t h e r ei s n o r e a s o ni t i s n ' t ,t n e n
y o u c a n t a k e s o m e s i m i c h r o m ea n d c l e a n t h e n e e d l e a n d
r e p o l i s h i t . R e p l a c et h e b l a c k r u b b e r s e a l w i t h t h e n e w
i m p r o v e do n e ( i t ' s b l u e i n c o l o r ) . T h e n e w r u b b e r s e a l a n d
g a s k e tw i l l s e t y o u b a c k t h e t o t a l s u m o f a b o u t $ 2 . 5 0 ,o r y o u
c a n p u t i n a w h o l e n e w a s s e m b l y p, a r t n u m b e r2 3 3 - 6 6 5T. h i s
new needleand seat assemblyis a $6.65item.
S i n c e y o u ' r e g o i n g t o h a v e t o h a v e n e w g a s k e t s ,p u m p s ,
d i a p h r a g m sa n d e t c .a t t h i s p o i n ty o u w i l l b e a h e a do f t h e g a m e
t o g e t a n R K - 1 0 2R e b u i l dK i t f o r t h e H L S e r i e so r t h e R K - 1 0 3
f o r t h e H R S e r i e s .T h e t o t a l c o s t f o r t h e k i t i s $ 1 3 . 9 6a n d t h e
racerdeal at most shops will be $10.75.
l f t h e n e e d l ea n d f u l c r u ma r m a r e i n g o o d s h a p et h e n g o f o r
t h e n e e d l er u b b e rs e a la n d g a s k e ta t $ 2 . 5 0a n d g e t a D G - S H L
g a s k e ta n d d i a p h r a g mk i t f o r t h e H L S e r i e so r t h e D G - 4 H Lf o r
t h e H R S e r i e sT
. h i s k i t w i l l c o s t y o u r a c e rd e a l$ 5 . 2 5 T
. h i sw a y
y o u s a v ea b o u t$ 3 . 0 0 D
. o y o u r s e l fa f a v o rh e r e .D o n ' tb u y a f t e r
m a r k e tc o p y T i l l o t s o nk i t s .T h e ys o m e t i m e sl e a k ,d o n ' tf i t r i g h t
a n d c a n c a u s et u n i n g p r o b l e m s .B o t t o m l i n e ! !l f t h e p a r t sa r e
not in a Tillotsonbag that is labeledwith blueand blackwriting
a n d s t a t e so r i g i n a l ,i t ' s c o p y p a r t s .A s e i z e dm o t o r o r a t u n i n g
problem is not worth the few cents thal you may saveup f ront.
L o o k a t t h e t h r o t t l es h a f t .l l i t h a s a n y w e a r o n i t , r e p l a c ei t .
S a m ew a y w i t h t h e r e t u r ns p r i n ga n d t h r o t t l ev a l v e .N o w t h e s e
items are tech parts. Bottom line! Don't be sanding,f iling or
p o l i s h i n go n t h e m . l f y o u d o , y o u ' r ei n l i n e f o r a D O .
Let's turn our attention to the needles.lf they are in good
s h a p ea n d t h e t i p s a r e n o t b e n t ,t h e n c l e a nt h e m u p . N e e d l e s
a r e a n o n - l e c h i t e m a n d h e r e I l i k e t o p o l i s ht h e t i p s o f t h e
needlesso that they are smooth lor the luel f low to go around.
I t g i v e st h e t u n ea l i t t l em o r es e n s i t i v i t yB. y n o w I t h i n k t h a t w e
have all the parts cleaned up and we are ready to put everything back together.
P u t t h e t h r o t t l es h a f t b a c k i n t o t h e c a r b u r e t o r .M a k e s u r e
that you don't get the throtlle place back in upside down or
t u r n e do v e rt h e w r o n g w a y . H E L P I I !H o w d o y o u k n o w w h i c h
w a y i s u p , d o w n o r o v e r ?E a s y .A l l t h e n e w e rT i l l o t s o nc a r b s
h a v ea t h r o t t l ev a l v ei n t h e m .T h e s eb u m p sg o i n t o t h e t h r o t t l e
s h a f ta t t h e b o t t o mo f t h e c a r bf a c i n gy o u f r o m t h e f l a n g ee n d .
T h i s w o u l d b e w i t h t h e c a r b t o p w h e r e t h e p u m p p l a t e sg o
f a c i n g u p . N o w i f y o u h a p p e nt o h a v e a t h r o t t l e p l a c et h a t
d o e s n ' th a v et h e t w o ( 2 ) b u m p so n i t , t h e n t h e r e i s a l i t t l el i n e
o n t h e p l a t e .l t l a c e s y o u a n d g o e s i n t o y o u r l e f t s i d e o n t h e
b o t t o m .W i t ht h e t h r o t t l es h a f ta n d t h r o t t l ev a l v eb a c ki n , m a k e
s u r et h a t i t o p e n sa n d c l o s e sa l l t h e w a y w i t h n o b i n d i n gt a k i n g
place. ll it doesn'tfeel free, loosen up the throttle plate screw
a n d r e - l i n et h e t h r o t t l ev a l v ei n t h e t h r o t t l eb o r e . B e s u r e t h e
throttle shaft is in the all the way closed position.
Now scratcharound in your bowl of parts and find the
throttle leverstop screw and spring. Put a spot of red Loctite
o n l h e t h r e a d s .N o w a d j u s tt h i s s c r e ws o t h a t i t j u s t c u s h i o n s
t h e b u t t e r f l yw h e n t h e t h r o t t l ei s c l o s e d .I n s h o r t ,s c r e wi t i n t i l
y o u j u s t f e e l i t t o u c h w i t h o u t o p e n i n gt h e t h r o t t l ep l a t e .T h e
w h y f o r t h i s I w i l l e x p l a i nl a t e r .
Now is as good a timeas anyto put lhe soft plug backinto
t h e c a r b .D r o p i t i n t o t h e l o w s i d ew e l l w i t h t h e c u r v e dp a r t u p .
W i t h l i g h t t a p s f r o m a s m a l l h a m m e r ,f l a t t e nt h e t o p o f t h e
w e l c h p l u g w i t h t e n d e rb l o w s .
P h a s e# 2 : L e l ' s p u t i n t h e n e e d l ea n d s e a t a s s e m b l y T
. his
o p e r a t i o ng e t s a l i t t l eb i t t r i c k y h e r e s o I ' m g o i n g t o g i v e y o u
. h e n y o u d r o p t h e g a s k e ti n t o t h e
o n e o f m y s p e e ds e c r e t s W
57
KARTERNEWS/ JANUARY 1993
bottom you seethat it won't line up deadf lush overthe holefor
the f uel to come thru. lt doesn'ttake a rocketscientistto f igure
o u t t h a t g o o d f u e l f l o w i s j u s t a s i m p o r t a n ta s a i r f l o w w h e n i t
comes to making horsepower.
How do you get the gasket over the hole and stay there till
you can get the seatback in? Look at the tool pictureagainand
y o u s e e a t o o lt h a t h a s a p i n t h r u t h e m i d d l e o fi t . O . K .N o w t a k e
a spot of red Loctite and put in on the top side of the gasket
o n l y .T a k ea n d s t i c kt h e e n d o f t h e p e n c i li n t o t h e h o l ew i t h t h e
wet side down and shakeit off . The next steDis to takethe tool
and screw it into the threadsof the hole till you lust feel it touch
t h e w a s h e r .N o w t a k e t h e p i n a n d p u s h i t t h r u t h e h o l e i n t h e
t o o l , g a s k e ta n d i n t o t h e a l l o y p a r t o f t h e c a r b b o d y . N o w
everythingis in perfectalignment.
T a k e y o u r s o c k e ta n d s n u g t h e t o o l u p s o t h a t i t i s p u t t i n g
pressureon the gasket.At this point pull the pin out and setthe
carb aside for a few minutesso the Loctite can set up.
T h i s i s a g o o d t i m e f o r y o u t o g o r a i dt h e f r i g .
Now getting back to your carb - you can removeyour tool. lf
y o u d i d e v e r y t h i n gr i g h t t h e g a s k e ti s s t u c kd e a do v e r t h eh o l e
in the carb. Now all you haveto do is put your seat back into
t h e c a r b a n d t i g h t e ni t u p .
L e t ' se n t e rt h e T W I L I G H TZ O N E :
N o w i t ' sg o i n g t o g e t a l i t t l et o u g h e rf o r m e b e c a u s et h e n e x t
step is to put the fulcrum arm back in and set the pop-off
p r e s s u r eo f t h e c a r b . W h a t ' sa f u l c r u m a r m ? F a i r a n d e a s y
q u e s t i o nT
. h a t ' st h e l i t t l ea l l o ya r m t h a t h a sa f o r k o n t h e e n d o f
i t a n d i t h o o k s t h i s f o r k i n t o t h e e n d o f t h e n e e d l e .T h a t p a r t
w a s n ' tt o o h a r d l o r e i t h e r o n e o f u s . N o w i t ' s g o i n g t o g e t
tougher on me. The pop-off pressure is what controls how
much fuel we get into the wet slide of the carburetor.The way
t h a t w e s e t i t i s w i t h t h e a m o u n to f s p r i n gt e n s i o nt h a tw e h a v e
o n t h e u n d e r s i d eo f t h e a r m . T h e w a y w e c h e c k t h i s i s a b i t
backwardslrom the way the carb works.
For one thing fuel pressureis not what blows the needleoff
t h e s e a t a n d l e t s t h e f u e l i n . W h e n t h e m o t o r i s r u n n i n ga t
differentRPM'sof the power band the amountof airflow going
t h r u t h e c a r b u r e t o ri s c h a n g i n ga t d i f f e r e n tp o s i t i o n so f t h e
throttle valve.The start of the RPM band and the bottom is
when we're in the processof startingthe motor. At this point,
for easy starting,the throttle valve is closed.
Never have the throttle plate set where the carb will idle.
Why? Thereare a lot of reasonsfor this. 1) lt's a racemotor and
I have never seen a race won at an idle speed. 2) Satety.
Rememberback at the very start when you laughed when I
s a i d " t h e T i l l o t s o nc a r b w i l l k e e p t h e m o t o r r u n n i n g w h e n
y o u ' r eu p s i d ed o w n o n y o u r h e a dt i l l t h e g a st a n kf e l l o u t . "N o t
q u i t et r u e . l t w i l l a l s o q u i t r u n n i n gi f t h e a i r s u p p l yi s s h u t o f f
w h i c h h a p p e n si f t h e c a r b i s s e t w h e r et h e t h r o t t l ep l a t eg o e s
a l l t h e w a y c l o s e d .3 ) O f f t h e s t a r tl i n ey o u n e e da l l t h ef u e l y o u
c a n g e t f o r t h e b r e a ko r t o p a s sa n o t h e rk a r t i n a t i g h t c o r n e r .
W i t hq u i c kf o o t a c t i o ny o u ' r em a k i n ga n a c c e l e r a t opr u m pa n d
a r i c h m i x t u r et o h a n d l et h e s e n e e d s .4 ) l t k e e p st h e m o t o r
f r o m g o i n g l e a n i n t h e t u r n s . I n s h o r t ,w h e n t h e t h r o t t l ep l a t e
c a n g o a l l t h e w a y c l o s e di t w o r k s l i k e a c h o k e .O . K . N o w t h i s
c h o k i n ga c t i o ng o e s r i g h t b a c kt o t h e p o p - o f fp r e s s u r eo f t h e
carb.
A r e y o u g e t t i n gl o s t ?D o n ' tf e e l l i k et h e L o n eR a n g e r S
. oam
l . L e t ' sr e - g r o u pa n d t h r o w i n a n o t h e rp h a s eo f t h e c a r ba c t i o n
that is part of the pop-off pressureand starting.
I n t h e s t a r t i n gm o d et h e t h r o t t l ep l a t ei s a l l t h e w a y c l o s e d .
A t t h i s p o i n t t h e m o t o r s t a r t st o t u r n o v e r .T h e o n l y f u e l p o r t
t h a t i s o p e n i s t h e o n e t h a t w a s u n d e rt h e s o f t p l u g t h a t ' st h e
c l o s e s tt o t h e f l a n g e p a r t o f t h e c a r b ( m o t o r e n d ) . W i t h t h e
t h r o t t l ev a l v ec l o s e da n d t h e m o t o rs p i n n i n go v e rt h e v a c u u m ,
t h e m o t o rs i d ei s p u l l i n gb u n c h e so f f u e lo u t o f t h e f u e l p o r t .A s
t h e f u e l l e a v e st h e c a r b ,o n t h e b a c ks i d eo f t h i s f u e lf l o w t h e r e
i s a v a c u u mb e i n gb u i l t u n d e rt h e d e m a n dd i a p h r a g mi n t h e
w e t s i d e o f t h e c a r b . T h i s v a c u u m i s i n t h e p r o c e s so f o v e r
r u n n i n gt h e p o p - o f fp r e s s u r et h a t w e s e t .
A s t h e v a c u u mb u i l d su p i t s t a r t st o p u l l t h e b l a c kd e m a n d
d i a p h r a g md o w n .T h e v a c u u mc o n t i n u e st o b u i l da n d k e e p s
p u l l i n g t h e d e m a n d d i a p h r a g md o w n t i l l i t c a n c e l so u t t h e
spring tensionthat we had when we set the pop-off pressure.
T h i s i s d o n e b y t h e a l l o y p i n p a r t o f t h e d i a p h r a g mw h i c h i s
p u t t i n g p r e s s u r eo n t h e e n d o f t h e f u l c r u m a r m . W h e n t h e
spring tensiongives up, the arm lifts the needleoff the needle
seat and the fuel rushes into the wet side of the carb. Very
s h o r t l yt h i s r i c h m i x t u r ew i l l f i n d i t ' sw a y i n t ot h e m o t o ra n dt h e
only way you stop it is to open the throttlewide open to cancel
o u t t h e v a c u u mo n t h e d e m a n dd i a p h r a g mW
. h e nt h i s s i g n a li s
cancelledout the spring tension we set comes back into play
a n d s h o v e st h e f u l c r u ma r m b a c k u p . T h i s l e t st h e n e e d l eg o
back into its seatto shut off the incomingf uel to the wet side of
the carb. When we open the throttle valve,this action also lets
m o r e a i r i n t o m i x w i t h t h e f u e l a n d t h e m o t o r s t a r t s .W a i tt o o
long on openingthe throttleand you fill the bottom end of the
motorwith fuel and load up a spark plug with wet fuel.No
a m o u n to f c a n d l el i g h t i n gw i l l n o w g e t t h e m o t o r s t a r t e d T
. he
o n l y c u r e i s t o p u t i n a f r e s hp l u g .
A t t h i s p o i n t y o u m a y b e t h i n k i n g ," W h a t p a r t d o t h e o t h e r
h o l e s u n d e rt h e s o f t p l u g o n t h e l o w s i d e , p l a y a t t h i s t i m e ? "
Goodquestion.
G o i n gf r o m t h e f l a n g ee n d o f t h e c a r b t o t h e a i r f i l t e re n d o f
t h e c a r b w e h a v ei n a T i l l o t s o nc a r b w h a t i s c a l l e da 4 c i r c u i t
c a r b .T h i s i s i n m o s t o f t h e H L S e r i e su n i t s .I n t h e H R a n d H D
Serieswe have,for the most part, a 5 circuit carb. In the new
s l i d ec a r b w e w i l l h a v ea p o s s i b l e6 c i r c u i tc a r b .
N o w , I ' m o p e n i n gu p a n o t h e rc a n o f w o r m s b u t , i t a l l g o e s
back to the pop-off pressure in the carb and needs to be
e x p l a i n e d I. n a 4 c i r c u i t c a r b w e h a v et h r e e o f t h e s ec i r c u i t s ,
u n d e rt h e l o w s i d e s o f t p l u g , k n o w n a s f u e l d i s c h a r g ep o r t s .
These three (3) fuel ports are controlled by the low side
n e e d l eT
. h e 4 t h c i r c u i ti s t h e h i g h s i d en o z z l ea n d i s c o n t r o l l e d
by the highsideneedle.
I n t h e H R a n d H D S e r i e sw e h a v e4 f u e l p o r t s u n d e rt h e l o w
sidesoft plug controlledby the low side needleand the 5th one
is the high side needlecontrolled by the high side needle.
Now when the throttle plate is in the closed positionthe first
h o l e i s c a l l e dt h e i d l ej e t a n d i s l e t t i n gf u e l i n t ot h e e n g i n e .T h e
t w o o r t h r e eh o l e st h a t a r e i n f r o n t o f i t a r e p u t t i n ga i r i n t ot h e
fuel at this time. As the throttle plate swings open and passes
each one of these holes the fuel ports change from being air
mixing orfices to fuel dischargeports. At wide open throttle
and under full racing speedall of these ports are putting fuel
i n t o t h e a i r s t r e a mc o m i n g t h r u t h e c a r b u r e t o r .H o w w e l l t h e
carb works and the overall power band is controlled by the
very careful balanceof the size of these holes and where and
how they are positionedin the carburetor.The amount of fuel
f low is (you guessedit) controlledby the pop-off pressureand
the positionwhereyou haveset the low and high side needles.
By now you should have all your lights turned on and
understandthat the pop-off pressurethat you set in the carbis
p r o b a b l yt h e m o s t c r i t i c a ls t e p i n b l u e p r i n t i n ga n y T i l l o t s o n
carburetor.Everythingworks around this pop-off pressure.lt
n o t o n l y c o n t r o l st h e a m o u n to f f u e l c o m i n g i n t o t h e w e t s i d e
o f t h e c a r b u r e t o rb u t , a l s o p l a y sa b i g r o l e i n c o n t r o l l i n gt h e
a m o u n t o f f u e l f o r t h e f u e l p o r t s t o d i s c h a r g ei n t o t h e m a i n
s t r e a mo f a i r c o m i n g t h r u t h e c a r b u r e t o r .T h e r e i s a n o t h e r
small hangerthat we haveto get out of the way beforewe can
set the pop-off pressureand it also plays a very importantrole
in the way the carburetorperforms.
T h i s i s t h e f u l c r u m a r m h e i g h ti t s e l fa n d i s m e a s u r e df r o mt h e
b a s eo f t h e c a r b t o t h e t o p o f t h e f u l c r u ma r m p a d w h e r et h e
p i n f r o m t h e d e m a n dd i a p h r a g mt o u c h e si t .T o s u m t h i su p : t h e
h i g h e rt h e f u l c r um a r m i s s e t ,w i l l s p e e du p t h et i m e s p a nt h a ti t
t a k e st o u n l o a dt h e p o p - o f fp r e s s u r ea n d l e t m o r ef u e l i n t ot h e
w e t s i d e o f t h e c a r b . T h e l o w e r t h e a r m t h e l o n g e rt h i s t i m e
s p a nw i l l b e b e f o r ei t u n l o a d st h e s p r i n gt e n s i o no n t h e n e e d l e
a n d s e a t .S o n o w y o u c a n s e e t h i s i s a n o t h e rv a l u a b l et u n i n g
a s o e c to f t h e c a r b .
W h a t ' st h e b o t t o ml i n e ?l f y o u h a v ea m o t o r t h a t w a n t s t or u n
hot or you need a little more fuel for tight tracks without
c h a n g i n gt h e a m o u n to f f u e lg o i n g i n t ot h e w e t s i d eo f t h e c a r b
JANUARY
1993/ KARTER
NEI,VS
58
then you set the arm on the high side. ll you need to make a
l i t t l em o r e e n g i n e h e a t o r d r y t h e c a r b o u t a b i t l o r m o r e t o p
end power,then you lower the arm height.
I just threw a big curve at you, didn't l? No problem. I'm
g o i n gt o g i v ey o u a s t a r t i n gp o s i t i o no n t h e s ea r m h e i g h t sa n d
y o u c a n f i n e t a i l o rt h i s s t e p a s y o u g o a l o n g t o f i t y o u r r a c i n g
needs.
In all gas carbs, I find that for kart racing,the best place to
startwith is at .085.Set this mearsurementwith a depth mikeor
a f u l c r u m a r m g a u g e l i k e t h e o n e s h o w n i n t h e p i c t u r e .O n
M e t h a n ocl a r b s ( H L o r H R S e r i e s )s e t t h e f u l c r u ma r m h e i g h t
at .065for a richer mixtureand torque. lf the needsare for top
endand a little leanerrunning carb then set this measurement
at.075.Now when you bend the arm to get this measuremenl
don'tjust tweak up one end so that it makesthe measuremenl
at the end of the fulcrum arm pad. Very carefullyuse a pair ol
smoothlaw pliersand bend the arm to the shapein the picture
so that the pad of the arm is 90o to the base of the carb.
Would you believethat we are getting closer to setting the
pop-offpressure?Not quite yet.
By now you should havelearnedthat the collapseor relaxat i o no f t h e s p r i n gt e n s i o no n t h e n e e d l ei s n o t t o t a l l yd o n e b y
the amount of the fuel pressuregeneratedby the fuel pumps
o n t h e f u e l d e l i v e r e dt o t h e n e e d l et i p . B u t a c o m b i n a t i o no f
b o t hv a c u u m b u i l t i n t h e w e t s i d e o l t h e c a r b a n d a s m a l l
amountof fuel pressure.Since we can't set the pop-off press u r ew i t h t h e m o t o r r u n n i n gw e h a v et o i m p r o v i s ea n d t h i s i s
wherethe pop-off gauge comes into place. By putting pressureon the f ront side ol the needlewe havean accurateway of
m e a s u r i ntgh i s p r e s s u r ew h i c h i n t u r n i s t h e s a m ea c t i o nt h a t i s
createdby the vacuum in the carb. The pop-off pressurethat
w eu s ei s a c l o s es t a r t i n gp o i n tt h a t h a sc o m e u p w i t h m i l l i o n s
o f r a c e t r a c k m i l e s a n d k n o w l e d g eg a i n e d b y e x p e r i e n c e .
Bottom line to this statemenl is: cut and try and keep good
records.Once you find what works lor you, write it down in
stonelor safe keeping. Very shortly here I'm going to start
g i v i n gy o u n u m b e r i n l b s . t o w o r k w i t h o n t h i s p o p - o f f
pressure.
F o ry o u t h a tt h i n kt h a t I f o r g o ts o m e t h i n ga n d h a v ea t r i c k u p
o n m e ,I ' m a b o u t t o p o p y o u r b u b b l e .T h i s i s t h e s p r i n gr a t eo f
t h e p o p - o f f s p r i n g s a n d i t ' s a l s o a n o t h e rt u n i n g f a c t o r t h a t
goeshand in hand with the pop-off pressureand the type of
needleand seal you use.
T h e r em u s t b e a b o u t 2 z i l l i o no f t h e s es p r i n g sl h a t c o u l d b e
used.They rangef rom soft rateto high rate;short to long.Yes,
t h e ye v e nc o m e i n d i f f e r e n tc o l o r s .B u t I ' m n o t t r y i n gt o t e a c h
you how to be a rocket scientist,so we're going to short cut
t h i so p e r a t i o n .
T h e n e e d l ea n d s e a t t h a t w e a r e u s i n g i n y o u r c a r b i s t h e
o r i g i n aTl i l l o t s o nw i t h a c a p t u r e da r m .T h e s p r i n gc h o i c e sa r e
n a r r o w e dd o w n t o t h r e e ( 3 ) s p r i n g s .1 ) S t o c k t h a t c o m e s i n
yourcarbthat we put therewhen we built the carb.2) EC-#001,
a s h o r t e rs p r i n g t h a t i s d o u b l e w o u n d o n t h e e n d s a n d i s
t u n a b l ew i t h . 0 0 5a n d . 0 1 0s h i m st h a tw e m a k e . 3 )P a r tn u m b e r
E C - # 0 0 3a,n o t h e rs p r i n ga b i t l o n g e rw i t h d o u b l ew o u n d e n d s
t h a tc a na l s ob e s h i m m e dT
. h e m a i nt h i n gh e r ei s t h a ti f y o u c u t
a spring and 99.990/o
of the time you have to get the pop-off
pressure
r i g h t ,y o u n e e dt o h a v ea f l a t e n d o n t h e s p r i n g .T h a t
i s w h y t h e E . C .S p r i n g sh a v ed o u b l ew o u n d e n d s o n t h e m . l f
y o u c u t t h e s t o c k s p r i n g w h e n y o u s h o u l d ,w i t h g r e a t c a r e ,
patienceand tweezers,re-bendthe end back to flat. This flat
e n d i s a m u s t f o r m a i n t a i n i n gc o n s t a n tp o p - o f fp r e s s u r e .
O n e t h i n g y o u d o n ' t d o i s n e v e r ,n e v e r s t r e t c ha p o p - o f f
s p r i n gi f y o u c u t i t t o o s h o r t .J u s t t h r o w i t i n F i l e ' 1 3a n d s t a r t
o v e r .A s t r e t c h e ds p r i n gw i l l g o b a c kt o b e i n gt o o s o f t a n d t h e
p o p - o f fp r e s s u r ew i l l d r o p o n y o u i n t h e r a c e .A r i c h m i x t u r e
w i l l s e t i n a n d y o u s t a r tw o r k i n gy o u r w a y t o t h e b a c k o f t h e
f i e l d .O r w o r s ey e t , y o u s t a r tt u r n i n g i n t h e l o w a n d h i g h s i d e
n e e d l e st o c u r e t h e r i c h p r o b l e ma n d y o u d r y t h e c a r b o u t o n
t h eb i g e n d .Y o u g u e s s e dt h e r e s to f t h e s t o r y .Y o uj u s t w e l d e d
y o u re n g i n ei n t o a o n e p i e c eu n i t .
P o p - o f fg a u g e sa r e j u s t l i k e t i r e g a u g e s .T h e y d o n ' t a l l r e a d
59
t h e s a m e .T h i s i s n o t w h a t y o u w a n t t o h e a r ,i s i t ? T h a t ' sw h y
when you set the air pressure in your tires you never use
someone elses tire gauge. Same way with pop-off gauges.
T h i s w a s s u c ha p r o b l e mf o r m e h e r ei n t h e s h o p t h a t I b o u g h t
a very expensive4.500inch faced gaugethat goesfrom 0 to 15
lbs. and is governmentcertifiedto be accuratewithn 1000/o
on
0 t o 1 5 b s . W h e n w e s e l l a p o p - o f fg a u g ew e h o o k i t i n t o t h i s
o n e a n d c e r t i f yt h e mt o f i t t h i s g a u g e .A f e w w i l l b e d e a dn u t o n
bul for the most part they will all be off as much as 1 lb. one way
of the other. What can I say?
l s t h e r ea w a y t h a t y o u c a n h a v ey o u r g a u g ec e r t i fi e d ?Y e s ,a
c o u p l eo f w a y s .l f y o u h a v ea b u d d yt h a t h a sa T i g w e l d e ry o u
c a n m a y b eg e t h i m t o l e t y o u h o o k y o u r p o p - o f fg a u g e i n t o i t
a n d b l o wt h e l i t t l eb a l lu p t o 1 0 l b s .N o w l o o k a t y o u r g a u g ea n d
s e e w h a t i t s a y s .l t i t ' s l i g h t o r h e a v ys o m a r k t h e g a u g et h a t
w a y a n d j u s t f i g u r et h i s c o r r e c t i o nf a c t o ri n t o y o u r s e t t i n g s l.f
y o u ' r eg o i n g t o l o s es l e e po v e rt h i s p r o b l e ma n d h a v en o o n e
with a Tig welderthat you can tap into, send your gaugeto us
a n d w e ' l lb e g l a dt o c e r t i f yi t o f f o u r g a u g e ,f r e eo f c h a r g e .J u s t
p u t a $ 5 . 0 0b i l l w i t h i t t o c o v e rt h e U . P . S f. e e st o g e t i t b a c kt o
you.
P o p - o f fg a u g e p r e s s u r e .I w i s h i t w a s a s i m p l e a s s a y i n g
everyonebuy a Ford,watch MondayNight Footballand setthe
p o p - o f fa t 10 l b s .i n y o u r c a r b .l t j u s t d o n ' tq u i t ew o r k t h a t w a y .
T h e f o l l o w i n g s e t t i n g sa r e o n l y a s t a r t i n g p o i n t l o r y o u . I n
s h o r t ,i t w i l l l e t y o u s h o w u p a t t h e b a l l g a m e w i t h a b a t .
S m a l l e n g i n e st h a t w o u l d b e r a n k e d i n t h e c l a s s e so f U S 8 2 0 ,T S - 4 0a n d C o m e rf a l l i n t h i s g r o u p .S e ty o u r f u l c r u ma r m
h e i g h ta t . 0 8 5f i r s t .R e m e m b e rt h e a r m n e e d st o b e b e n t w i t h
the diaphragm pad 90' with the base. Pop-off pressurefor
t h e s ee n g i n e sw i l l r a n g ef r o m 1 0 l b s .t o a h i g ho f 1 4 l b s .w i t h 1 2
l b s . b e i n ga g o o d p l a c et o s t a r ta t . R o t a r ym o t o r s :8 t o 1 2 l b s .
w i t h 1 0 l b s .b e i n ga g o o d p l a c et o s t a r tw i t h t h e f u l c r u ma r m s e t
at .085with .075being the highest.
T h e H R - 1 8 1H
, R - 1 8 4a n d H R - 1 9 1 ' s : W i tthh i s s e r i e so f c a r b u r e t o r sa n d t h e l e v e lo f t h e d r i v e r ss k i l lt h e p o p - o l fp r e s s u r e
c a n b e a n y w h e r ef r o m 6 l b s .t o 1 2 l b s .w i t h t h e f u l c r u ma r m s e t
at .085off the baseol the carb. Look at the suggestedstarting
p o s i t i o na n d p i c k t h e s e t t i n g st h a t f i t y o u r n e e d s .
T h e f i r s t s t e p o n t h e a g e n d ai s t o t a k e t h e f u l c r u ma r m a n d
w i t h v e r yf i n e s a n d p a p e ar n d p o l i s h i n gc o m p o u n d ,r e m o v ea l l
o f t h e s h a r pe d g e s .T h e m o s t i m p o r t a n tp l a c e sh e r e i n t h e s e
s t e p si s w h e r et h e f o r k i s t h a t f i t s i n t o t h e n e e d l ea n d t h e s i d e s
w h e r et h e p i n g o e s t h r u . W i t h t h e f u l c r u ma r m p o l i s h e du p
w h e r ei t l o o k sl i k ea n e w s h i n e yd i m e ,d r o p t h e n e e d l ei n t o t h e
s e a ta n d h o o k t h e a r m i n t o p l a c e .N e x t ,p u t t h e p o p - o f fs p r i n g
u n d e rt h e a r m a n d c h e c kt h e a r m h e i g h t .K e e pt a k i n gt h e a r m
i n a n d o u t a n d s h a p ea s n e e d e dt o g e t t h e d e s i r e dh e i g h ta n d
t h e p a d o f t h e a r m 9 0 o t o t h e b a s eo f t h e c a r b .O n c e y o u a r e
s a t i s f i e dt h a t t h i s o p e r a t i o ni s d o n e p r o p e r l y ,c l e a n t h e f u l c r u m a r m ,p i n a n d s c r e w .P r e s s u r i z ebdr a k ec l e a nw o r k sg o o d
l o r t h i s .Y o u s h o u l dh a v ey o u r n e e d l ea n d s e a ta l r e a d yi n t h e
c a r b .S p r a ys o m e b r a k ec l e a nd o w n i n t o t h e s e a ta n d w a s h i t
o u t g o o d .N e x td r o p t h e n e e d l eb a c ki n t o t h e s e a ta n d h o o k u p
t h e a r m . S l i p t h e s p r i n g u n d e r i t a n d t i g h t e ni n t o p l a c e .N o w
p u s ht h e a r m d o w n t o o p e nt h e n e e d l ea n d l l o o d t h i sa r e aw i t h
W D - 4 0 .P l u g y o u r p o p - o f fg a u g e i n t o t h e { u e t i n l e t t r a c k a n d
check the pop-off pressure.
N o w c o m e st h e f u n p a r t .C u t , s h a p ea n d t w e a kt i l l y o u g e t
t h e p o p - o f fs e t t i n gt h a t y o u n e e df o r y o u r c a r b u r e t o rR
. ememb e r ,n e v e rs t r e t c ht h e s p r i n gi f y o u g o t o o s o f t .N o w y o u k n o w
w h y I m a d et h e s es h i m st o f i t i n t h e b o t t o mo f t h e s p r i n gw e l l .
O n e t h i n g v e r y i m p o r t a n to n t h e p o p - o f f p r e s s u r ei s t h a t i t
m u s t p o p a n d h o l d w i t h o u t d r o p p i n g .A 1 l b . d r o p i s a c c e p t a b l e .I n s h o r t ,y o u s e t t h e p o p - o f fp r e s s u r ea t 1 0 l b s . ,i t p o p s
a n d t h e n e e d l ec a n d r o o b a c ka m a x o f 1 l b . A t t h i s o o i n ti t m u s t
h o l d f o r s o m e p e r i o d o f t i m e . A v e r y s l o w s e e p a g eb a c k i s
a c c e p t e df r o m t h i s l o c k p o s i t i o n .B u t i t m u s t b e v e r y s l o w t o
n o n e .N o n ei s b e t t e r .l f t h e n e e d l ew o n ' t p o p a n d h o l d ,r e m o v e
t h e n e e d l ea n d r e - c l e a ne v e r y t h i n gC. l e a nt h e s e a tw i t h a Q - t i p
a n d b r a k ec l e a n .l f e v e r y t h i n ge l s ef a i l s ,r e - p l a c ew i t h n e wa n d
c l e a np a r t s .W i t ht h i so p e r a t i o nd o n e ,i t ' st i m ef o r a p i t s t o pa n d
K A R T E RN E W S/ J A N U A R Y1 9 9 3
N o w y o u ' r e r e a d y t o s t a r t t h e e n g i n e .S e t t h e k a r t o n t h e
starting grid and have it pointed at the race track. Pointedat
t h e p r i v yo r s o m e o n e ' sp i c k - u pj u s t c o u l d l e a dt o m a j o rp r o b lems.Neverget into the kart without beingdressedto race.Put
yourselfin the kart,hit the throttle a couple of timesand watch
t h e l i n k a g eo f t h e c a r b . M a k e s u r e t h a t i t i s g o i n g f r o m f u l l
throttle and haveyour handler put the starter into the starter
n u t a n d s p i n t h e m o t o r o v e r .W a t c ht h e f u e l c o m e u p t h e f u e l
l i n e .A s s o o na s i t d i s a p p e a r isn t ot h e c a r b ,c o u n tt o t w o a n d h i t
the throttle.The motor should fire.
l f t h e c l u t c h i s s e t u p r i g h t ,y o u ' r es t i l l i n t h e p i t s . l f n o t ,
y o u ' r eo n y o u r w a y t o t h e t r a c k .N o w y o u k n o w w h y y o u d i d n ' t
point your kart at the privy. Hold the brake on and throttle the
e n g i n ea f e w t i m e st o g e t t h e c l u t c h t o h o o k u p a n d m o v eo u t
o n t o t h e t r a c k .l f t h e m o t o r i s l o a d y ,g i v e i t a c h a n c et o c l e a r
o u t b y i t s e l f .l f i t w o n ' t ,y o u m a y h a v e t o t a k ea t o u c h o f t h e l o w
s i d ea w a y .T u r n t h e n e e d l ei n a l i t t l eb i t a t a t i m e u n t i l t h em o t o r
c l e a n su p . A s s o o n a s t h e m o t o r c l e a n su p b r i n g st h e l o w s i d e
needleback out where it was. Give the kart a couple of lapsto
w a r m u p . O n c et h e m o t o ri s w a r m e du p ,c o m e d o w n t o p a r a d e
lap speedthen stand on the throttle.lf the motor bogs, it could
b e o n t h e l e a n s i d e . O p e n t h e l o w s i d e n e e d l el u s t a t o u c h .
K e e pc o m i n go u t w i t h t h e l o w s i d en e e d l ei n s t e p so f / et u r n t i l l
the motor pulls hard from the parade lap speed.
N o w y o u ' r er e a d yt o f i n d t h e t u n e f o r t h e h i g h s i d e .O n t h e
longeststraightaway,bring the high side needleout till it goes
r i c h i n t h e m i d d l e .T h i s r i c h s o u n dw i l l b e a s p l a t t e r i n gs o u n d
o r i r r e g u l a rf i r i n g . B e t t e rk n o w n a s 4 - c y c l i n g .O n c e y o u t i n d
t h i s s p o t ,s t a r t t a k i n g t h e h i g h s i d e i n t i l l i t r u n s c l e a n a l l t h e
way to the end of the straightawayand just 4-cycles at the
p o i n t w h e r e y o u ' r eg o i n g t o l i f t f o r t h e t u r n . O n c e y o u h a v e
f o u n d t h i s s p o t ,t a k et h e h i g h s i d en e e d l ei n l u s t a t o u c h m o r e .
Now go backto paradelap speedand makesure it pulls off the
b o t t o mc l e a nw i t h n o b o g g i n g .
Next checkthe feel ol the motor as you just come off the turn
after a high speed straightawayflat footed. lf the motor 4c y c l e sh e r e ,t h e l o w s i d ei s j u s t a t o u c h o n t h e r i c hs i d e .T a k ea
l i t t l ea w a yf r o m i t . ( T u r n t h e n e e d l ei n . ) W a t c hy o u r t e m p e r a turegaugeA
. n y t h i n go v e r 3 5 0 "i s s t a r t i n gt o g e t t o o h o t . l f y o u
don't havea temperaturegauge on your kart and the stickers
startto melt off the side of your helmet,that is also a good sign
that the motor is running on the hot side.
Once you are comfortable that the motor is tuned right,
come back into the pits and check the positionof the needles.
l f y o u f i n d t h a t t h e h i g h s i d e n e e d l ei s o u t m o r e t h a n t h e l o w
s i d e n e e d l ey o u m i s s e di t s o m e w h e r eo u t o n t h e t r a c k .W h e n
y o u ' r et u n e d a t t h e o p t i m u m ,t h e l o w s i d e n e e d l e sw i l l b e o u t
j u s t a t o u c h m o r et h a nt h e h i g hs i d e .O n c ey o u h a v ef o u n dt h i s
p l a c ef o r t h e n e e d l e sy o u c a n s t a r tf i n e l i n i n gt h e t u n e b y t h e
p l u g c o l o r a n d t e m p e r a t u r eo f t h e m o t o r .P l u g c o l o r w i l l b e a
light tan to brown color. Motor temp 250o to 350o max on a
control. A lot of people tell me that a TS-40 or US-820has to
run 500" plus to makegood power.Try 375' and put your stop
watch on it. Just maybe 500" is not the hot tip after all.
O D D SA N D E N D S ;
Never mix up any more fuel than you need for race day.
Dump left over fuel into your race hauler.Never use left-over
fuel for parts wash.
Service carb after every race meet. When pumps get
stretched,replacethem. Stretched pumps make for a richer
r u n n i n gc a r b u r e l o r .
O n r e a l h o t d a y s e t t h e p o p - o f f p r e s s u r ea b i t h i g h e r .T h i s
w i l l l e t y o u r u n t h e n e e d l e so u t f u r t h e ra n d h e l pc o o l t h e m o t o r
o f f w i t h o u tb e i n gt o o r i c h o n t h e t o p e n d .
C o o l w e a t h e r ,g o o d a i r , h i g h A . D . S e t t h e p o p - o f f j u s t a
touch lower.Carb can stand to be a touch richer.
When setting pop-off pressure never have carb dry. Wet
everythngwith WD-40 for safetyfactors.
Whenputting in new gaskets,wet them with your 2-cycleoil.
T h i sw a y ,i f y o u h a v et o p u l l a t r a c ks i d es e r v i c ey o u w o n ' th a v e
g a s k e t ss t i c ka n d t e a r o n y o u .
P o p - o f fp r e s s u r em u s tp o p t h e n d r o p a t o u c h a n d h o l d . l f i t
a t r i p b a c kt o t h e f r i g .
With the pop-off pressureset, the rest is all down hill. Now
it's time to put the rest of the carb back together.lf you have
h a d a c a s e o f b r a i n f a d e o n h o w t h e g a s k e t s ,p u m p s ,d i a p h ragms and pump platesgo, look at the parts break-down
d i a g r a ma n d p i c k t h e c a r bt h a t f i t s y o u r s .I h a v ea l l t h e s ep a r t s
i n l i n eo n t h e w a y t h e y g o b a c ko n t o y o u r c a r b .
A s y o u p u t t h e g a s k e t sa n d p u m p sb a c ki n i t ' sa g o o d i d e at o
c o a tt h e m w i t h a b i t o f y o u r 2 - c y c l eo i l .T h i s w i l l h e l pt h e ms e a l
plus if you have to do race track work on the carb, a gasket
won't stick and breakon you. After the carb is all backtogether
it's a good ideato pressurecheck it and makesurethereare no
leaks in the pump stack.The way you do this is to very caref u l l y b o t t o mo u t t h e h i g h s i d e a n d l o w s i d e n e e d l e sD
. o n ' tg e t
carried away here or you can kill the carburetor.Now hook
y o u r p o p - o f fg a u g et o t h e t o p o f t h e c a r b t o p a n d p u m p i t u p .
Your gauge will go to where you set the pop-off pressure.lt
will pop then drop back a touch. Now you can keep on pumpi n g a n d i t w i l l g o o n u p t o 1 5 l b s .l f t h e n e e d l e sa r es n u g ,i t w i l l
h o l d a t t h i s p o i n t . l f t h e n e e d l e sw o n ' t h o l d ,w e t t h e i n s i d eo f
t h e c a r b w i t h W D - 4 0a n d s e e i f i t ' sc o m i n g p a s tt h e n e e d l e sl.f
n o t ,t h e nw e t t h e o u t s i d eo f t h e c a r ba n d l o o kf o r a i r b u b b l e s l.f
t h e r e i s l e a k a g ea r o u n d t h e p u m p p l a t e so r c a p , p u t a l i t t l e
m o r e t o r q u eo n t h e s c r e w s .B o t t o m l i n e .T h e c a r b c a n ' th a v e
a n y a i r l e a k so n t h e o u t s i d eo f t h e p u m p so r c a p . S o m es e e p a g e a t t h e n e e d l e si s O . K .a n d w i l l n o t h u r t t h e p e r f o r m a n c eo f
the carburetor.lf you don't have any parts left over you did a
good job and we are ready to go to the race track.
No matterwhich seriesof carburetoryou're using thereare
s o m e t e l l t a l e s i g n st h a t w i l l h e l p y o u d i a l i n t h e p o p - o f fp r e s sure to meet your racing needs.After you havethe carburetor
back togetherand are at track side,if you f ind that the motor is
v e r y s l o w i n c o m i n g b a c k f r o m f u l l t h r o t t l e p o s i t i o nt o t h e
bottom of the RPMscale,the pop-off pressurecould be settoo
h i g h . M o t o r w i l l c h o p o f f g o o d b u t e n g i n eh e a ti s o n t h e h i g h
s i d e .K a r tw o n ' tc o m e o f f t h e t u r n h a r do r i s s l u g g i s hw h e ny o u
stand on it from paradelap speed.
The other side of the coin: Pop-off pressure is too low.
H e a v yl o a d u p p r o b l e m s .F u e l d r i p p i n g o u t o f t h e h i g h s i d e
nozzle.High and low side needleshaveto be turnedto closeto
bottoming out. Heavy blue smoke when you're at racing
speed.Plug color is very dark to black.Theseare just a few of
t h e s i g n s t o l o o k f o r t h a t l e t y o u k n o w w h e r ey o u ' r ea t . l t a l l
goes back to seattime and the more you have,the easierit will
get.
Another question tht you may have and has been asked of
m e a z i l l i o nt i m e s .W h i c hw a y i s t h e b e s tw a y t o m o u n tt h e c a r b
o n t h e e n g i n e .P u m p su p , p u m p sd o w n ,c a r b u r e t o o
r n i t ss i d e .
l'll try to answer it this way. Bottom line. The carb was
d e s i g n e dt o w o r k w i t h t h e p u m p s o n t h e b o t t 6 m .W h e n t h e
carburetoris mountedthis way it hasa tendencyof leaningthe
c a r b o u t o n t h e t o p e n d . S o m e t i m e st h i s m a k e st h e p o w e r
b e t t e ra t t h i s p o i n to f t h e R P Mb a n db u t ,y o u d o l o s ea t o u c h o f
mid-rangetorque. Also, on real long tracks you can flat suck
t h e c a r b o u t o f f u e l . T h i s h a p p e n e dt o m e a t C h a r l o t t ew i t h
J o e y L u n a t t i ' sc a r b u r e t o ra n d s o m e o t h e r s .T h e r e I h a d t o
r e m o u n t t h e mw i t h t h e p u m p so n t h e t o p . B o t t o ml i n e .l t ' sa l o t
e a s i e rt o m a k ef u e l r u n d o w n h i l l t h a ni t i s u p h i l l .T h e c a r b u r e tor laying on its side. Only if you have to. This position can
c a u s ea i r b u b b l e sa r o u n dt h e n e e d l ep o c k e t sw h i c hw i l l c a u s e
l e a na n d r i c h c o n d i t i o n si n t h e c a r b . l f y o u m u s t p u t t h e c a r b
o n i t s s i d e t h e n I w o u l d s u g g e s tp u t t i n g t h e n e e d l e so n t h e
b o t t o m .T h e y m a y b e h a r dt o f i n d t h i s w a y b u t t h e c a r bt u n i n g
w i l l b e m o r es t a b l e .
You pros can go raid the f rig again. Entry level racersread
on. School is not out yet.
Y o u r T i l l o t s o nc a r b e a r n e d t h e r e p u t a t i o no f b e i n g " u s e r
f r i e n d l y " b e c a u s ei f y o u g o t a n y w h e r ec l o s e t o t h e a b o v e
i n f o r m a t i o ny o u c a r b w i l l w o r k f o r y o u . T r a c ks i d et h e r ea r e a
f e w s i m p l es t e p st o f o l l o w o n f i n d i n g t h e r i g h t t u n e o f y o u r
c a r b . 1 ) S e t t h e l o w s i d e n e e d l ea t 1 %t u r n s o u t f r o m b o t t o m
a n d t h e h i g h s i d e n e e d l ea t 1 t u r n .
JANUARY1993/ KARTEFNEI,YS
60
d o e s n ' th o l d c a r b w i l l n o t p e r f o r mr i g h t .W i l l a l w a y sb e o n t h e
r i c h s i d e .C u r e : r e c l e a nn e e d l ea n d c l e a ns e a tw i t h Q - t i o a n d
wD-40.
A l w a y sc a r r y a s p a r ec a p , f u e l s c r e e na n d c o r k w i t h y o u . l f
c a r bs t a r t sa c t i n gl e a n ,p u l l c a p a n d c h e c ks c r e e n .l f t r a s hi s i n
i t ,r e p l a c ew i t h b r a s ss c r e e na n d h o p et h a t n o n eo f i t g e t st o t h e
n e e d l ec, a u s i n gi t t o l e a k .
T o r q u ec a r b p u m p p l a t e sl i k e y o u w o u l d a c y l i n d e rh e a d .
E v e r yo t h e r o n e t i l l t i g h t . A n y l e a k s h e r e w i l l c a u s e l o t s o f
t u n i n gp r o b l e m s .l f l a p t i m e s a r e n o t f a s t , i t ' s a l w a y se a s yt o
b l a m et h e p r o b l e mo n t h e c a r b . B u t j u s t m a y b ey o u w i l l f i n d
t h a tf a s t e rl a p t i m e b y t u n i n g t h e d r i v e ro r t h e c h a s s i s .
Keepyour fuel dry and have a good time at the races.
KIT
WITH
E.C.
COMPLETE TURN KEY
FLOI{
ALL
THE WHISTLES AND BELLS:
BENCH DESIGNED AND BUILT
FOR DIRTI
ENDURO OR
STREET RACING.
ASPHALT,
WHEN WIN
IS
THE
ONLY
WORD YOU
KNOW. THIS
KIT
IS
YOUR TICKET
FOR
LIFE IN THE FAST LANE.
POP-OFF GAUGE: THIS
IS
TOOL FOR EVERY RACER.
A MUST HAVE
I}EYMIM
2s
PLUS
W.K.A.
NATIONAL
CHAMPION
KNOWS
THAT
E. C. I S
CARBURETION TRIX
AND WORK
MANSHIP
IS
CHEAPER THAN
SOMEONE
ELSE I S MISTAKES.
.'UST
MAYBE
I F
YOU HAD
AN
E. C.
( CenSUnETOR,
TRICK
OR
Tr{O
REED
V A L V E r M O T O RI O I L O R ? )
.'OEY MIGHT
F]NISH
SECOND AND YOU WIN ALL THE
MARBLES. ONE
THING
FOR
SURE, T
D O NI T
I
C A R E W H OI S
BEHIND
THE
B. C RAM
FLOW SUPER SEAL RED TIP
NEEDLE AND SEAT KIT;
FOR GAS OR
ALKY. ALSO COMES WITH CAPTURED ARM
AND NEEDLE
WHEN NEEDED OR
HIGH
FLOW ALLOY NEEDLE FOR HR-191.
STEERING
WHEEL,
I
GIVE
LLO% TO
YOUR RACING NEEDS THE DRIVING
AND
G E T TI N G T H E W I N ,
I
LEAVE THAT UP
TO YOU.
M y 2 5 p l u sy r s .E x p e r i e n c ies c h e a p e trh a ny o u r M i s t a k e s .
1309 old charlotte Pk .,Dickson,Tn.370s5. Pl{.615-416-6 t07
61
,I
rl
for
us
as
tha
thi
ne
Ma
ca
cyc
w.
dif
an
mi
the
the
Bo
bet
the
one
B u t d u e t o t h e s i z e otfh i s t e c hp i e c e i t cou
will haveto be brokendowninto more tec
thanoneissueanyway.
Soanychanges tec
that aremadefor 1989 we will coverat
wil
a laterdate.
anc
Dur Strolcen
l n s h o r t ,f o r t h e c o s t o f o n e B e n
I t d o e s n ' ts e e ml i k e t e n y e a r sh a v e
youcan getaTlS VenturiTillpassed
sincelhungupmyleathersand Franklin
retiredmy Motocross
otsoncarb,manifoldandfilterkit. Now
bootsto the back
takeoff thestocktankandcarbandbolt
of the closet. But I had come to the
point of time where twenty yearsof
Remove
on the newcarbassembly.
the
racinghadtakenitstoll,and
f ueltankf romthekartandcleanoutthe
motorcycle
Ok, so nowyou knowthe sizeof Tillrustand crudthat got therefrom being
the everyweeken-d
of barto barbattling
.
ll
o
t
s o ny o uc a n u s e i s . 8 7 5 + . 0 1 5 =
p a c k e fdu l l o f l e a d ] P l u g o an f u e ll i n e l
w i t h t h e y o u n gl i o n sw a s d i s h i n go u l
l9r
:
m o r e p u n i s h m e ntth a n t h i s o l d w a r
i i t t u p t n e t a n k w i t h a r x y l a n O b i n g o , y o. 8u9 0 , o r ' 8 7 5 - ' 0 2 5 . 8 5 0 . N o ww e
pag
going
that you already abl
are
to
assume
just
horse'sbodycouldtake. In short lwas
have
movedinto ihe Super"Si6cf
knowthatthe moreairyoucanmovethe
fallingoff moreand healingup a lot
classind a newwarto f ight.Forsomeof
l9t
you will makefor the
more
horsepower
slower.And to make it to work on a
you making the chanle to a Super
but
Mondaymorninglwasgoingtohaveto
Stockerisn-onlgdealbeiauseyou
have m.ostpart.So it's just naturalthat you
con
t u r n t o a s p o r t t h a t w o uO
l Oe al o t e a s i e r c o m e f r o m t h e Z c y c l e r a c i n g s c e n e a nwdi l l b e l o o k i n gf o r a c a r bt h a t i s f r o m cha
o n m y o l d b o n e s . s o l t u r n e d t o K a r t i n g .h a v es o m ef e e l f o r t h e T i i i o t s o n
c a r - . B 9 0 t o . 8 T 5 a t t h e s m a l l e s t p a rtthoef
you
venturi.Bottomline, air is like water, ture
Thisgaveme a \ryay
to retirein the fast
buretor.But for thoseof you, which is
lanewithoutthe pain,and notturn into
about 98%, movingup' f rom a Box thebiggerthe holethe moreyoucanget' alv
throughit (mostof the time).
a couchpotato.
Stockcarb with one main jet and a
ont
needlethat doesn'tdo muchwhenyou
not
In the lastten yearstherehasbeena
moveit, the stepto a Tillotsoncarbcan
Now beforeyou HorstmanGoldCup
1.1
lot of changesin the sport of Karttng. be a nightmare,and needless-to-say
runners,and Briggsand StrattonDirt
a
l.s
frighteningtrip. But once you havea
racersstart snickering,rememberfor
Someclasseshavebeendropped,and
tha'
plan of attackthis new carb with two
somenewoneshavetakentheir place.
the most part you only, at the best, bec
As with any sportyou haveto havea
adjustable
needlesand enoughsmall makeup 10% of the racersthat go by
big
guideline,andrulestogobysoallknow partsto frll a soupcancomesout being W.K.A.Rules.The other 90% of the anc
whatballgamethey'rein.
Beingaracer, just as simpleas yourBoxStockcarb racersthat readthis is the locallevel sidr
l , l i k e y o u , s o m e t i m e sd o n ' t l i k e
a n d a s d e p e n d a b l ae s a b a l l p e e n r a c e ra, n d t h e M o m a nPdo p r a c e t r a c k so f r
changes;
but to growand be a success, hammer.
andclubsthattreatourW.K.A.Manual
and
as their DevineGuidedScripture,
waveshaveto be made.But takeabout
tThereis nothingquitesosimple,and
they read it totally
threeminutesand lookback,eachand
- kdifferent
n o w l e d gthan
e . T you
n i s j r t ibec
t
i
m
e
a
t
t
h
e
s
a
m
e
t
t
[
q
]
i
:
l
|
:
$
,
:
:
3
u e c i u s e otfa c k o f
e v e r yc h a n g et h a t h . ; ; ; ; ; ; i . ; ;
Mar
carburetor'
Yourdictionarvlllltellv,gu, cL ts pointedout to the ne-wcomer
be- cyc
w.K.A., our powerr r co.ti.;-;.;
correctly,that a carbureLo,f merelya
iarse tromthis groupof racersis where see
beento the betterme.ioi t[. ip.jri rnj
ll
devicefor mixingfuel with air'
our nextyear'sirop'of nationalracers i n l
the racer.
wjll
comefrom.But all youJoeHereos the
one of the best thingsthat w.K.A.
In your lg8g w.K.A. Tech Manual
welcome
to readon'
are
ma
hasdoneforKartingwas-threeyearsago
you will find in tne sufer sio.r,lri.t
HL
theybrought
in a newclassstructure
for
thatrtsays:AnyTl8Tillotson
carburetor
pointin time we will assume H L
thefourcycleclasscalledSuperstock.
withbuttirflythrotileassembly.
Venturi ^, At this
t h a ty o u k n o wa b o u ta s m u c ha b o u at
HL
T h i sc l a s i w a s s e t u p a s a s t e p p i n g m u s t r e m a i n s t o c k u p p l . " = r e ' ; ' t h
Tillotson
Aunt or
carb as your72-year-old
stonefor the racerthat wantedto move
doublepumperstacks,i"onginu?l
iivl.
Martha,who'sonly concernis howto the
outoftheBoxStockfourcycleclassandon top of carburetor.r.ro*'ror rriijd
makea betterpicklethan Milly down Ver
intothefasterlane;butnotto thespeed theremaybe somectrange;tolhe tec;
t h e r o a d f o r n e x t y e a r ' s p i c k l e c o n t e son
tat
w h e r eh e c o m e si n w i t h b o n ew h i t e
o f t h i s c a r b ;a n d a t f t r ' e - t i m e
(where
going
you're
Fair
to
the
County
"t-in.
an(
knuckles,
andpuckermarksall overhis
writingof thistecharti.ieurlirreoottor
seatcover
aftereachheat.
tinedecisions
have
not6..n 'oLo'-on. 3: ?dlirnifl.tffi.$tj;andracevour the
62
Things
aregoingto geta bit confusing
forthe momentbecauseI'm havrngto
u s e o u1r 9 8 8W . K . AT. e c h n i c aMl a n u a l
guideandyou'rereading
asa reference
thisin our 1989TechManual.To make
thingsa bit moreconfusing
for youthe
newcomer,
when you study your Tech
youwill f ind somedifference
Manual
in
carbtechspecsbetween2 cycleand 4
cycle.
Thereason
forthisis because
our
W.K.A.Manualis put togetherby two
differenttech boards,one for 2 cycle,
andone for 4 cycle. Thesetwo committeesdon't meet together.In short
theyarebothin the sameworld;but for
themostpart can be light yearsapart.
Bottomline:youhaveto be ableto read
between
the lines;but don't evermake
themistakeof assumingwhat'sok for
oneis ok for you. A mistakelike this
couldgetyouD.Q.whenyougo intothe
techbarn.lf youareeverin doubtabout
tech,call a tech boardmember.They
willhelpyou,that is whattheirjob is,
andtheywill get youon the righttrack.
only havetwo pump plateson them.
Alsothe drill patternunderthe welch
p l u gi s f o r g a sI.n s h o r t t h e y w i l l r ul ena n
on your4 cycleSuperStockmotor,and
if youtry to useoneof thesecarbsin its
stockformyoustanda verygoodchance
of turningyourmotorinto a one piece
unit.Hangin here,I will showyouhow
to convertone of these gas Tillotson
carbsto Alky so that you can use it on
yourSuperStockmotor.
But first I knowwhat'sin yourmind
onthisVenturisizedifference
onTechif
theyareall supposeto be 718Tillotson
carbs.Thisis myopiniononthismatter.
Forone,the 2 cyclepeopledon't feel
that as longas the Venturiof the carb
staysunder.900 it will makeno differenceon the outcomeof the race. ln
shortthereis no powergainson a differenceof .010 herein the venturisize.
Alsotherehasbeenand is somenewHL
carbs that have come into the States
that areverycloseto this .900 sizedue
to the molds being used by Tillotson
today.
In short they are cuttingthe 2
lf you look back on page63 of your
cycle
racer
a little slackat this point.
M
a
n
u
a
l
y
o
w
u
i
l
l
f
i
n
d
a
w
h
o
l
e
1988Tech
Now
I
that
Techfor 1989 is going
think
pageof Tillotsoncarbs.Thispageprobto
be
changed
.890 MaxVenturiwith
to
ablyhasbeencarriedoverintothis new
part
the
visual
of
the Tech beingde1989Tech Manualwith no changes;
leted.
lf
is
this
the
casethen we will
you
very
but betterreadboth
closelyand
coverwhatyoucando herein oneof the
comparethem word-for-wordfor any
partsof this Techarticleto come.
changes.
Upon thetop left handcorner latter
For
now
we will leaveit at this point if
youseethe wordcarburetor
with a picthe
visual
is removedfrom the carb
tureofa Tillotson
carbunderit. Youwill
venturi.
By
hand, not with any power
alsonotethat this carbhasthreeplates
tools,
remove
the sharpcastingridgein
ontopofthe carbbody.Alsothoughyou
the
Venturi
with
600 sandpaper.Don't
n o t et h a t i t s a y s T i l l o t s o nV e n t u r i
getcarriedawayandsandyourwayinto
1 . 11 0 ,H R 1 8 4 - i 8 1 ,M a xT h r o t t l B
e ore
a D.Q.problem.ln shortmakesureyou
1.325.Well,youknowrightoff the bat
they put in for a
thatthis is not the Tillotsonyou need don'tgo pastwhatever
your
is realcloseto
NO-GO
.
.
.
lf
carb
because
the Venturiof the carb is too
big,Asyou readon you hit the jackpot the N0-G0 it may be smartto leaveit
andseedownon the lowerright hand a l o n e .
By nowI havebecomeasconfusedas
sideof the pagethereis a wholepassel
you are, so it's time for a shortrecap,
of carbslisted.
andclearup the air some.In shortyou
wherethingsget a bit cloudy can use any HL carb on your Super
Here's
you're
into a part of the Tech Stockeras long as the venturi is no
because
biggerthan .890 and if the visualis
Manual
that is put togetherby the 2
liftedit won'thaveto beascastedin the
cycleboard.One problemis hereyou
seethatthe maxVenturiis .900 where venturi.ln shortyou can standoff any
inthe4 cycleTechpartof the manual sharpedges.Alsoin an updatein rule
changesyou will be legalif you use a
theNo-Gosizeof the Venturiis .890
pumpthat is gettingits pulsefrom
fuel
m a x ;b u t a l l o f t h e s e l i s t e d c a r b s ,
the
intake
manifold.Butif youdecideto
H L - 2 2 7A , H L - 2 5 0 A , H L - 3 0 7 A ,
convert
one
of the gas carbs to your
H
L
3
1
7
E
,
a
n
d
H L - 3 0 4 AH L - 3 1 7 A ,
thenI advisethatyouput
H L - 3 2a2l lc o m ef r o mT i l l o t s oans a 7 1 8 SuperStocker
ontopof
o r . 8 7 5 V e n t u r ic a r b . I n s h o r ts i n c e thethreepumpplateassembly
thesecarbswrll meet Tech as far as the carb.In shortyouneedall the help
Venturi
of them youcangetto getthefuelup to a Super
sizeyoucanuseanyone
Stockerbecauseof the way the cam
on your SuperStocker.But there is
another
oroblemhereand that is that works.To converta gascarboverto an
thesecarbsareall gascarbsand they alkycarbgoto yourlocalshopandgeta
R K - 1 0 4 - HrLe b u i l dk i t ,o n e6 7 3 8 i n l e t
63
v a l v eb o d y ,o n e 1 9 8 3 0 5 f u e l p u m p
body,one 91A303 diaphragmcover,
anda oackof 95.174 stackbolts.You
nowhaveall the partsthat it takesto
turnthegasTillotsonintoan Alkycarb.
youstillhavea carbthat
But remember
wasdesigned
to runongas,andthedrill
p a t t e r ni n t h e c a r b w i l l h a v e t o b e
changedand calibrated
for yourSuper
Stockmotor.
All of the abovehasslecan be eliminatedby usinga 7/8 Tillotson
carbwith
the partnumberof HL-314.Thisis a 4
cyclecarband if it's listedin the Tech
M a n u aIl c a n ' tf i n d i t . W h yd o n ' tt h e y
lust sayin the 4 cycleTech partof the
manualusethis carbthat is madefor
the 4 cyclemotor?| feel the reasonfor
thisis because
of twothings.(1) Engine
buildersor racerscan take any of the
other 7/8 carbsand make them work
with somemodsto the carb. (2) The
HL-314Tillotson
carbwasdesigned
by
H o r s t m a nP r o d u c t s a
, n d W . K . A .t o
makeit fai torall the speedmerchants
(trynotto blowanyone'shornif theycan
helpit.) Whichis fair. lt's not rightfor
youto be told that you must usesomeone'sball gamewhenthereare others
on the marketthat will fill the bill for
you,andstayin theguidelinessetdown
by the Rule Board.This is the way it
shouldbe.All I'm sayingis, if youstart
off with a HorstmanHL-314carbyou
won't haveto go out and try to find a
bunchof partsto get your motor into a
b u i l d i n gs t a t e . P l u s t h e r e m u s t b e
1 0 , 0 0 0p l u sH L - 3 1 4c a r b so u t i n t h e
f ieldalreadyandmoreon the boatto the
goodold U.S. of A. today.As of now
thereis anothernewTillotson
carbthat
hasbeenbroughtintothe Statesfor the
4 cycleracer,Thiscarb is beingbuilt
anddistributed
by Benfieldcams.Part
numberfor this carb is HL-336Aand
you can find it at all the betterKart
Shops.
Whrlewe're on the subjectof new
tricksTillotsonhassomenewcarbsin
the worksfor the kartracer,2 cycleand
4 cycle.Amongthesenewcarbsthere
w i l lb ea 1 . 0 0 0i n c hc a r bf o rt h eO o e n s .
Lookforthesenewcarbssoon.I'vebeen
told we will have them for this new
1 9 8 9 r a c i n gs e a s o cn o m i n gu p .
The basicrequirement
tor any carburetoris that it metersthe f uelandair
in suchproportrons
asto be easilycomb u s t i b laen dh e n c e n a b l e
t h ee n g i n teo
produce
goodpowerovera wideR.P.M.
band,Nowto get yourmixerto do all
thisforyouon the racetrackyouneedto
u n d e r s t a nadl i t t l eb i t a b o u th o wa T i l -
lotsonworksbeforeyoucanf ix it, or set
madeby Gem Productsand the part
it up to f it yourracingneeds.But since numberis G4464.At thesametimeyou
t h i s i s n o ta n a r t i c l eo n h o wt o c h a n g e getthegaugeget3 ft. of Gem'sG4516
t h ee n g i n e e r i no gf t h e H L - 3 1 4c a r b w
S P3 / 1 6 l . D .f u e ll i n e .T h er e a s o Ins a y
, e
t h i so nt h ef u e ll i n ei s b e c a u sG
will just hit the highspotson howthe
e e mh a s
a f o r m u l a t i o no n t h i s l i n e c a l l e d
carbworks.
F - 4 0 4 0 - AT. h i si s k i l l e rl i n ea n dw o n ' t
, T A G EL E F T :
E X I TR I G H TS
g e th a r dw h e nu s e dw i t ho i l o r a l k yG. e m
Likeany workoperationto be done alsomakes
the samelinein 1/4forf uel
youneeda fewspecialtools,andsome
l i n e .P a r tn u m b e irs G 4 5 1 8 - S PA. s f a r
partsbeforeyoustartthetaskat handto
as f iltersgo we will waiton thatonetill
set up yournewSuperStockride.First we seewhatTechis for 1989 andgo to
on the list you need to get a I2XI2
the f lowbenchwhenwegetto that part
pieceof glass(at least1/8 inch thick) of the problem. you
lf
can't wait and
fora surfaceplate.A coupleof sheetsof
haveto do yourthing now.Just get a
6 0 0 w e t d r y s a n d p a p e r ,T i l l o t s o n Horstman,
Gemor whoeverf ilteradapD G - 4 H Lr e b u i l dk i t , a n d a p i n t o f
t o r a n do u t aK . & N . f i l t e r o ni t f o r n o w .
WD-40.Just as well get a gallonof
L a s t o n o u r s h o p p i n gl i s t o f t h i n g s
WD-40,it'scheapandyouwill be using neededis an intakemanifold.Horstit likewaterbeforewegetdone.Andlast
manManufacturing,
I feelhasthe best
onthelistyouwill haveto havea pop-off ballgameherebecause
theymakethree
gauge.My choiceof pop-offgaugesis
differentlengths
of manifolds
to choose
from,andyouwill f ind anyoneof them
at your better go-kartshops. In the
manifoldchoicethereis one long,one
short,andonein the middle.Theonein
the middle is my choice85% of the
time. Partnumberfor this manifold
is
4HM2-A.I like the waythis manifold
pullsin the midrange
andontop.Nowif
the tracksthat you run on mostof the
time hasa lot of on off the throttletypes
of turns,andyoufeelthat youneedan
edgein the torquedepartment
thanyou
maylike the longmanifoldbetter.Part
numberfor this manifoldis 4HM3-A.
The 4HM-4Ais a realshortmanifold,
Thisis an all out top end manifold
and
best usedwlth a slide carb and open
motors.In short, too short for your
SuperStocker.
ThenewTillot
it'sgoingto be.NEWTRIX:
andwhata season
sonCarbsthat I told vouthatwereon the waterto the
Partnumberfor these
Statesarenowin thewarehouse.
newcarbsare HL-334-A
TheHL-334-A
andHL-337-A
Carb
overkilltrick.ThisCarbhasa newbodvthatis a lot
thananHL-3i4Carb.Theventuri
of thiscarbhasbeen
BenchDesigned
andBuiltto get maxair through
a smaller
hole.
0nlyproblem
is in its stockformit'snot a 7/8
Carb.Theventuri
of thiscarbis 3/4 in it'sstockformout
rswrittenit says:
thebox.AndthewaytheTechManual
7/8 inchventuriTillotson
withbutterflyasseml
carburetor
Ventury
maynot be replaced,
measurement
.875+.015
- . 0 2 5 .C a r bm u s tr e m a i ns t o c ka p p e a r i nwg i t hd o u
pumper
stacksof original
styleon top of carburetor.
tom line,as the Techis writtenthe carbwon'tmake
Lavoutof TeeSlot
through
theTechBarn.Sureyoucouldgrindthenumbers
thebottomof thecarb,andyoucouldboretheventuri
out
maketheTechsize,buttheoutside
of thecarbcasting
is
differentthat whenyou lay it on the benchwithother7
lUorry I left you hanging
for a coupleof issueson this
Carbsit willstickout likea sorethumb,andtheywill
partof theTillyBlueprint
youthatwhat
setup.Butto assure
youoncatch#3 (Carbmustremain
stockappearing).
gottheirTech
I tellyouwon'tgetyouD qd,I waitedtilll.K.F.
I knowI'ma bitof anOutlaw,
anda longhaired
Hippy
Manual
for i989 out,andtimeto crosschecktheirTech
Tenn.,
I
feel
for
but
the
betterment
of
the
the
Tech
Sport
against
W.K.A.
Tech.Surewouldmakeit easierfor theRacmatter
this
could
be
changed
read
Tillotson
to
any
ersif Techwasthe sameas it usedto be in thepastwhen
part
tor withbutterfly
assembly,
diameter
at narrowest
bothsidesof thefenceusedthesamerules,Thisis notthe
venturi,
.900.
lf
Tech
was
this
way
then
I
could
use
one
timeor theplaceto get intopolitics,
andopinions
arelike
my
2
carbs
my
cycle
on
Super
Stocker
or
Limited.
Then
hyneeies,
weallhaveone,andbestI keepmineto myself
for
HL-334-A
carbwith
now.Myinterest
nowis to helpmakeyoumorecompetitive, the otherhandI couldusethiscarb
pump.
not
3/4
bore
and
have
to
use
fuel
For
sure
a
the
andnotgetyouDqd.intheprocess.
tor wouldmakemoretorqueandwhoknows,justmaybe
youwillneedto geta
Bytheway,if you'renewto W.K.A.
wouldbe the fastestwayaroundthe racetrack,For
youneedtheTechSpecsfor
W.K.A.
Techmanual
because
thereis a lotof 3/4 venturi
carbsoutinthefieldthatare
yourmotor.Alsopart#1 of thisTechArticleis in theretoo.
looking
for a raceto goto. Buttillourpowersincontrol
ln short,without
it, it'slrkegoingto themovies
andwalking timeto studythematterandcanmakea decision
on
intothe middleof the plot,not knowing
whether
to make
bestfor all,I advise
thatyoudon'ttry to modthiscarb
love,holdthelight,or fight.
For
trv to be Techin the SuoerStockor Limited
Class.
justdidn'tfalloffa
RECAP,
FALLOW
UP,BACK
UP,andoddsandendsof TRIX mostparttheW.K.A.
TechOfficials
you.1989is uponus
coming
andNEWS
ingTurnip
thatwillinterest
Truck,andto outfoxoneof themyouhaveto
|t
64
Butfor a Modified
up awfully
earlyin the morning.
or Open
classMotorthisis the carbthatwillgiveyouall the metal
you needto do yourthing.In shortyouthoughtthe .980
Hartman
wastrick;waittillyouseethisone.
Nowas far as the HL-337Trllotson
Carburetor,
no Tech
problem
here.Thiscarbis thesameas an(almost)
HL-227-A
withthebrasstubeinthemouthof theairhorn.Thisletsthe
carbpulsethe air intoandoutof theair filter.Somewhere
downthelinewewillgetto theFlowBenchandwastea coupleof daysandseewhat'shereinthesenewTrrxfromTillotson but for nowdon'tmakewavesfor yourselfandtrick
yourself
youcan'tbeattheTechBarn.
outof a winbecause
As you learnto buildmorepoweryou get in returna
fasterrideandat thispointyouneedto worrymoreabout
safety.Oneof thesesafetypointsI feelneededis a third
beanngsupport
for theflywheel.
lf youhaveeverhada flywheelblowup on youor brakeoff a crankandcomeout
through
the blowercoveryouwillknowwhatI mean.Gem
products
makesa goodthirdbearing
support
andI'mgoing
to do a lot of testingwithit andbringthe resultsto you.
Onlyproblem
asof yet:theyarenotlegalto racewith.Why?
BeatstheH- outof me.Butyoufor surecanuseit during
practice
thentakethe sideplateoff comeracetime.For
sureyourSuperStocker
is goingto loveyoufor
or Limited
supporting
the5 lb. plusfly wheelfor as muchtimeas possible.WhileI'monthepointof safetyWildBillHolaway
down
Gawayis building
fly wheels
for theopensandtheywillbe
readyfor Barnsville.
Billwillhavetwo different
models,
one
willbefor battery
spark,andtheotheronewillbe a magnet
typeso you can use eitherthe MacCoilor the Briggs
Magtron
Coil,Moreon this later.Forsurea hellof a new
yearis in themaking
for theW.K,A.
Family,
andit'stimeto
getdownto business.
As I suspected
theTechon thevisualhasbeenliftedon
SuperStockandLimited
Carbs,ln shortyouthenewcomer
youknocked
don'thaveto worryaboutbeingD'qd.because
youwillgetbounced
theburrsoutof yourcarb.(Butin l.K.F.
in the SuperStockClass;but notthe LimitedClass.)
So if
youthinkyou'regoingto go HeadHunting
ontheotherside
of thefence,betterhavetwocarbsfor yourSuperStocker
at thismoment.
TheymayliftthisTechproblem
beforethe
yearis out because
theywouldliketo haveyoucomeand
racewiththem?LastyearW.K.A.
andLK.F.wereWorlds
apartontheirrulesandwhatwouldoassW.K.A.
Techfor the
mostpartwasnotcompetitive
in anl.K.F.
race,andanl.K.F.
motorwasn'tevenableto getby thefrontdoorof a W.K.A.
TechBarn.BottomLine,no matterhowgoodyourunyou
haveto winthefourthheat,or thethirdonerf it'sraining
beforeyougo homeasthewrnner
witha fullsackof marbles.
Let'sget backto the business
at handon Blueprinting
yourMixer.By nowyouhavehadtimeto gatherup allthe
partsyouneedto workwith,so graba cupfullof yourfavoritebrewandletsexitto the shopandseeif we canfind
somemorehorsepower.
YourTillotson
Mixeris a 4 circuitcarbworkingoff two
stages.Lowsideneedleandhighsideoff the highneedle.
0n the low srdeneedlewe havea threeholedrilloattern
controlled
by thelowspeedneedle,
Wewillcomebackto
howthesethreefuelportsaffectthe powerbandof your
motorina littlewhile.Forthemoment
weneedto go
though
to thefueltankandworkourwayfromthereto thepointof
building
a fireintheengine.
Aswithanyengine
thefuelsupply
needs
to beclean.0n
Drill1/B holein softplug.
Wrtha hooktooltakecareandpryout softplug.
65
a SuperStockerdon'thavethe fuellineanylongerthan
needed
andalsousea goodfuelfilterin the line.Thefuel
pump(toppartof thecarbwhereyouplugonthefuelline)is
pump.Thepressure
vacuum
diaphragm
a pulseoperated
pulseis supplied
fromthe engine
andthe pulsecyclesare
wall,and
up anddowncylinder
bythepistonrunning
created
the opening
andclosingof the intakevalve.ln a fourcyle
Tillotson
manifold
thereis a holedrilledintothe mounting
partof theflangeon ananglewhichcomesoutintothemidThemounting
flangeof yourcarbhasa
dleof themanifold,
holein it also,andwhenboltedto the manifold
thesetwo
andcarbasholeslineuowitheachother.Withthemanifold
theintakevalve
semblyboltedto the motorandit'drunning
is opening
andclosingwhichletsthe pistoncreatea negapulsewave.Thispulsewaveis transmitted
tiveandpositive
way.The
through
thispassage
to the pulsepumpchamber
vacuumpart of the pulsecyclecausesthe fuelpumpdiaphragmto moveintothe pumppulsechamber
creating
a
vacuumin the fuelpumpchamber
thatallowsfuelto flow
pastthe
screen,
fromthefuelinletthrough
thefuelstrainer
Thevacuinletcheckvalveandintothefuelpumpchamber.
closestheoutletcheckvalve
um in thefuelpumpchamber
cycle.
during
thispartof thepumping
partof thepulsecycleforcesthefuelpump
Thepressure
creating
a pressure
intothefuelpumpchamber
diaphragm
pump
it
fuel
through
the
fuel
forces
out
of
the
on the
that
thefuelinletsupplychannel
outletcheckvalve,andthrough
closesthe inlet
to the inletneedlevalve.Thefuelpressure
cycle.Theinlet
checkvalveduringthispartof thepumping
the pressure
surgesof
andoutletsurgechambers
diminish
the pumpsysthefuelandprovide
steadyfuelflowthrough
tem.
Bottomlineas youcanseethereis a lot goingon inside
of yourcarballthetimethemotoris running.
yourunintoarefuelleaksandair
Thetwomainproblems
willmakeyourcarbperleaks.Eitheroneof theseproblems
formlikea Turkey
anddriveyouup a treetryingto getyour
andif
motorto runright.Airleaksarethebiggestproblem,
yougetonein anypartof thecarbyou'reinfor a problem
in
thetunedepartment.
Let'sget the carbto
STEPNUMBER
ONE:AIRLEAKS.
sealup andbe airtight.First,takethescrewoutof thetop
of thecarbthatholdsthefuellineto thecarb.Withthecap
At thispointnoteif
off,remove
thecorkgasketandscreen.
thecorkgasketfits tightlyin place,lf it doesn'tget a new
comein a carbkit andwillhaveto
cork.Thisgasketdoesn't
Makesurethat
is 95174.NOTE:
beaskedfor.Partnumber
is cleanandbrassin color.Thereis a silver
thefuelscreen
is for a gas
screen
alsofor theTillotson;
thissilverscreen
carbandis a realfinemeshandcanandwillpluguponyou
veryeasy.Andsinceit takesthreetimesthealkyovergasto
onfuelstarrunyourmotoryoucan'taffordto takea chance
vation
here.
the six screws
Withthetop of the carboff nextremove
the pumps.
thatholdthe pumpto the carb,andseparate
howthey
Lookat thewaytheycomeapartandremember
gotogether.
onhowtheyare
lf youforgetlookat thepicture
stacked
andgo bythatwhenyouputyourcarbbacktogeth-
Makesurecarbis flatin millvicebeforecuttingteeslot.
fl
it
c
h
s
tl
fr
h
s
h
u
v
c
s
0
Witha 1/4 endmillcuttheteeslotin thedottedlines.
66
fl
u
E
c
t
U
S
or
Withthepumpsoffthecarbyoucanseetheinsideof the
carbandtheFulcrum
armandpin.At thistime(ifthecarb
hassometimeonit)lookat thetopof thefulcrum
armand
seeif thereis a dentwornintotheendof thearm.lf thereis
a
c
d
b
I
g
il
s
Finished
teesiotrsnowreadyfor deburring.
l'l'.
:{t:.:.
t:!:l
With
lines.
a 1/4endnillcuttheteeslotlnthedotted
a dentwornintotheendof thearm.lf thereis a denthereit
c o m e sf r o mt h e c o n t a c p
t o i n to f t h e p i n o n t h e b l a c k
diaphragm
demand
andwillneedto be replaced.
Partnumberfor thefulcrumarmis 155A24.Whileyou'reat it better
getaboutsixpop-off
partnumber248345.Wewill
springs,
getto the reasonfor the needof six springsafterwhile.lf
thecarbis newthenyou don'thaveto removethe brass
seatfortheneedle.
Nowat thispointif thecarbis usedyouneedto remove
thewelchplug,partnumber17955.lfthecarbis newleave
it alone,
thereis no needto removethe welchplug.lf the
you
carbis usedyouhaveno choicein thematter;because
haveto take rt out to makesurethat the low sideof the
sumpis cleanandbe ableto checkthedrillpattern.
Getting
thisplugoutif donewrongcanruinthecarbso beverycarefulat thispoint.Thewelchplugis only.035thickandyou
haveto drilla holein the middleof it so thatyoucanput a
smallhookin the holeandpry the plugout.Theproblem
hereis thatthebottomof thesumpis only.100at thebest
thewelchplug,andif you'renotcareful
inyourdrilling
under
youwillgo rightout throughthe bottomof the low side
justthrowit in the roundfile,and
lf thishappens
chamber.
startalloverwitha newcarb.Witheverything
apartourfirst
is to surface
operation
thethreepumpplatesandgetthem
flatso we canassureourselves
of no air leaks.Lookat figure# for the sidesof the pumpsthatneedto be surfaced.
Break
outyoursheetof glassandput a sheetof 600 wet
on it. Nowtakesomeof yourWD-40
drysandpaper
andwet
thepapergood.Let'sstartat thebottomandworkourway
upto thetop.Lookat platenumber
threerealcloseandyou
seea castingringthatis aroundthe holethatleadsto the
pressure
pop-off
Fuelpassage
thatyou
through.
check
it.
fuelwell.ThisplateI havedonetwowayswhensurfacing
(1)Justletthatpartof theplatehangovertheedgeof your
glassandtakecarenotto honeoff thelittlering.(2)Takea
flatfileandbeverycareful
andfiletheplateflat;butdon'thit
the sealing
ring.(3)Don'tworryaboutit andjusthonethe
holeplateflat.I'vedoneit allthreewaysandat thrspointfeel
it makesno difference
onewayor the other.Theothertwo
platesjusthonethemtilltheyaredeadflat.Afterthe plates
arehonedwashthemwithhotwaterandsoap.
Nowwithallthe plateshonedflatwe canturnour attentionto the carbbody.Justin frontof the fulcrumarmyou
Remove
the
seetwoholes,oneoverthetopof eachneedle.
twoneedles,
andnotethattheneedles
arethesame;butthe
onethatcameoutof thelowsidehastwobrasswashers
on
it. Be surethatyouputthisneedlebackintothe lowside.
Thereason
for theextrabrassneedle
is so
on thisneedle
thatyoucan'tscrewthe needlein too far anddamage
the
lowsideneedleseat.Fora SuperStocker
thesetwo fuel
feederholesfromthefuelchamber
for the
to the needles
mostpartwillhandle
allthefuelthatthecarbneedsto feed
themotor.Butif youlikeat thistimeyoucantakeanddrill
outtheholethatfeedsthelowsideneedle
to .185,whichis
thesamesizefeeder
holeonthehighside.ThiswillhelpasI
sureyouof morefuelfor the lowsideneedle
if needed.
won'ttakeanychances
of running
dryso I preferto TeeSlot
my carbs.Lookat the picture
for wherethetee slotgoes
andat figure# for whata finished
teeslotlookslike.Again
hereis a placewhereyou'rewalking
onthinicewhenyouput
thisslotin.I usea 7/4 endmillfor theteeslot,andit may
beto yourbenefit
to haveanykartshopthathasanendmill
to dothisoperation
foryou.
Nowlet'sturnour attention
backto thewelchplugarea
andthelowsidesump.lf thecarbis newI advise
thatyou
don'tmessaround
withtheseholes.lf thecarbrsusedyou
needto checksizeof theholes.
Hole#i, closest
to themanifoldis .038,the middleholeis .059,andthethirdhole,
closest
to the back,andon an angleis .046.lf yourcarb
plusor minus.002
doesn'tfall intothesemeasurements
for a Limit
thanthecarbmorethanlikelyhasbeenredrilled
ed or OpenMotor.lf thisbe thecasethanthecarbmayrun
too richfor a SuperStocker.
Nowdon'tgetmewrongat this
pointbecause
thereis a lotof otherdrillpatterns
thatEngine
Builders
usefor SuperStockers.
Butthesearecustom
oat
ternsthatfit a certaintypeof track,or camsetup.Sothat
you can understand
this a littlebetteryou needto understandwhatthesethreeholesdo in thelowsidesump.Let's
go to #1 holefirst.Thisholeis thecarb'sprimary
idlefuel
port,andwhenthethrottle
goestotallyshutthisis
discharge
thefuelportthatletsthemotorstartandidle.0n thetrack
thisholealsohasa bearing
onhowhardyoucomeoffa corner.Anytimeyoubackoff the throttlethisholeis the only
oneworkingandputtingfuelintothe motor.Theothertwo
fuelports,oneinthemiddle
toward
andtheoneonanangle
theairfilteraremixing
airat thistimeintothefuel.Backon
thegasandas thethrottle
valveswingsonthebacksideof
the middleholeyou'reintothe midrangepartof the carb,
is nowthe
andfor a heartbeat
thebackhole,aircorrection
At thispoint
onlyportthatis mixingair intothefuelcharge.
you'realsostartingto get somefuelsprayfromthe high
sideneedledumptube.At full throttleall threeholesare
puttingfuelintothe carb,plusthe highsideis alsoat full
the sizeof anyof
song.So nowyoucanseeif youchange
justthat part of the
theseholesyournot onlychanging
you're
carb'scircuit,
alsochanging
thetopendaction
of the
car0.
Nowto finishuptheblueprint
of yourcarbtherearethree
morekeyfactorsthatyouhaveto understand
andtakecare
of.(1)Needle
andlastand
andseat,(2)Fulcrum
armheight,
(3)pop-off
pressure.
Thesethreepointscan
mostimportant
bea bucket
andsendyouto theFunny
Farm.
Any
of worms,
change
thatyoudo to onewilleffecttheoutcome
of theother two.In shortallthreehaveto be in tunewitheachother
powerband
fromthetimeyoucomeoff
to geta cleanpulling
thestartlineto maxR.P.M.
Tomakemorehairpulling
time
throwin somehardleftandrighthandturnswherethemotor
plumbdownto thebottombasement
is pulled
line,thenfor
finishing
touches
throwin a straightawayof 700 feetplus
wheremotordemands
areso highthatthemotorrattlesand
hangs
a rodoutthesideof theblocksometimes.
Beforewe can attackthrsproblemyou needto understanda lrttleon howthispartof the carb'scircuitworks.
When
airstartsrushing
themotorlights,
downthethroatof
thecarbandrntothe motor.Fuelis berngpulledoutof the
go up thehrghsidedump
lowsrdesumpandas theR.P.M.
tubealsostartsa fuelstreamintothe motor.As the fuel
comesoutof thecarbandmixeswrththeairgoingintothe
motorvacuum
is beingmadeinthewetsideof thecarbby
pullstheblackdemand
thefuelrushing
out.Thrsvacuum
diaphragm
prnloads
down,andthepressure
of thedraphragm
theendof thefulcrum
arm At thepornt
wherethepressure
of thefuelonthefrontsideof theneedle
onthepumpsrde
greater
andthewetdraphragm
becomes
thanwhatthepop
68
theyallholdthefilteron.
Filter
takeyourchoice,
adaptors,
fromit's seatletting
is the needleis released
off pressure
morefuelintothewet sideof the carb.Fromthispointthe
fuelis nowableto makeit'swayintothe lowandhighside
anyoneof these
needles
andon intothemotor.Bychanging
pornts
youcanchange
of fuelthatgoesintothe i
theamount
it fit yourtrackneeds.
wetsideof thecarbmaking
andseat.Forthemostpartthe i
Firstlet'slookat theneedle
fuelforthemotorde'
andseatwillpassenough
stockneedle
Problem
thatyoucanrunintohereis thattheneedle
mands.
dirtyonewayor theotherby junkinthe
andseatbecomes
fuel,or whatI callwhitealkydeathwhichmakesa powder
to notseat
builduo in thecarb.Thiswillcausethe needle
goesdownthe
carbresponse
andleak.Whenthishappens
tube.In shortthe motorstartsrunningrichon youand
goesaway.A goodsignthatyouaretoo
peakhorsepower
rich:themotorgoesflaton thetop end,or justplumbcuts
off on youwhenyou'reflatoutfor anylengthof time.Cure
for thisproblem
is to makesurefuelis cleanandafterevery
raceyouflushthecarbwithgasafterracedayis over.How
do youflushthe carbwithgas?Whenyoufinishyourlast
heatpullyourkartintothe pitsandpullthe fuellineloose
fromthetank(makesureyouhaveshutoff thetankvalve).
Nowbe verycarefulandtakea pintcan(emptyCokecan
worksgood)of gas andputthe fuellineintothe gascan.
youcouldget
AgainI stressthatyoubeverycareful
because
Nowstartyourmotor
burnt,or worseyettorchyourGo-Kart.
in
andasthegasstartsto go intothecarbrunbothneedles
someso themotorwrllrun.Lettheenginerunlongenough
to pushallthegasoutof thecarbandthemotoris running
on gas.lf youfinishin thetop of thefieldandyouhaveto
putyourkartintoanimpound
areafor Techyoumaynotbe
ableto startthe motoron gas andflushit out.So at this
pointyouwillhaveto revertto planB.
Nowmakesurethatyouget an OKfroma TechStewart
withyourmotorandlet himknow
beforeyoustartmessing
youcouldget D'qd.for messing
whatyou'redoingbecause
gaugeandfillup
withthe motor.PlanB: Takeyourpop-off
nowplugit ontothetop of thecarband
thelinewithWD-40,
gaugepumpWD-40
withyourpop-off
throqgh
the carband
pushallthealkyoutof it. Thiswillsaveyourcarb;butrunningthemotoron gasis stillthebestwaybecause
themotoralsogetsflushed
andthishelpslubethetopend.
pressure
Fulcrum
armheightandpop-off
arethelasttwo
pointson getting
the
changeable
thefuelto thewetside.of
carb.Bothof thesertemsrelateto eachotherandallthe
combinations
thatyoucando herewouldfill up thiswhole
magandwestillwouldn't
coverallof them.SoallI candoat
thispointis giveyoua running
start,hitthehighspots,and
youcarrytheballfromthere.Asyouchange
thearmheight
youalsochange
the pop-offpressure
of the spring.I know
whatyournextquestion
is. What'spop-offpressure?
Fair
i
I
i
without
theendof thespringbeingflat.lf youdon'tmakethe
endof thespringflatit neverdoesthesamethingtwice.The
pressure
7 lb. pop-off
is a middleof the roadpressure
and
youmayhaveto movethis2 lbs onewayor the otherto fit
yourneeds.lf youhavea fuelpumpon the motoryouwill
haveto raisethepop-offpressure
a touch.
position
with
needle
start
the lowsideout 1 1/2
As for
rounds,andthe highside1 turn.Thiswillget you on the
fromthisoornt.
trackthentunethecarbasneeded
filter
Air filtersand
adaptorsare a directrelationto the
#.
amount
of airthatyoucanputintothemotor.Figure
Filteradaptors
comein all stylesandshapesfrombeing
justa simpleroundcuplikeHorstman
andGemmaketo the
moreexoticvelocitystacksofferedby the Horsepower
MerMypointhereis notto popanyone's
bubble;
chants.
butona
boxstock7/8 Tillotson
carbona SuperStocker
Motorthere
is notenough
airbeingdrawnintothemotorfor anyof these
velocitystacksto reallydo thejob theyare builtfor. Nowif
thecarb,manifold,
camandetc.hasallbeensetupas a toworking
tal
unit
off
a FlowBenchthat'sa wholenotherball
Safety
is theneedandyourmotorwillloveyoufor usingit.
game,andthistypeof velocitystackwillget youfasterlap
question,
you'renewandneverbeenherebefore. times.Bottomlineif youboughteverything
enough
thatwas 1 to 3
pressure
Pop-off
is howmuchpressure
it takesfor theneetimesfasterthatyoureadaboutyoucouldwintheracewithdleto comeoff its seat.lt'seasierfor meto saythisthanto
outevertakingyourkartoff thetrailer,Mainthingon a Super Stockeris to keepthe dirt out of it, anda Gemor
how;because
howwe checkit andsetthepop-off
explain
is
Butwe'redoing
different
thanhowthecarbmakesit pop-off.
Horstman
or a velocitystackwitha goodfilteris the most
thesamethingas the carbdoeswhenit buildsvacuumin
important
thing.
thewet sideof the carbandpullsthe demanddiaphragm
Whendo you knowif you haveyourcarb right?Whenit
down.
At thispointtheaboveis aboutas clearas muddywapumpsfuelupthefuellinein a HeartBeat,runslikethefamiter;buthangintherewe'regoingto makertyet.
ly stationwagonon the bottomandhasthe top endof an
Underthe fulcrumarm is as youfounda smallspring.
Thisspringis pushing
up on thefulcrum
armandthearmis
pressure
pressure
is
applying
ontheneedle.
Andthepop-off
howmuchpressure
it takesto pushthis springand arm
downandrelease
the needlefromthe seatso fuelcanget
intothewetsideof thecarb.Whenthemotoris running
this
pressure
fromits seatis applied
thatreleases
theneedle
to
putonthe
thespring
fromtwoforces.(1)Fromthevacuum
demand
fromthecarbintothe
diaphragm
bythefuelflowing
motoras it runs.(2) Fromthe pressure
of the fuelpushing
fromthe pumpson top of thecarb,and
against
theneedle
pumpif youhaveonehookedup.Withyour
fromanoutside
pop-oJf
gaugeyou are simulating
thesetwo forcesfor setpointonthefrontsideof the
tingpurposes
froma pressure
needle.
HAPPENS
WHENYOUCHANGE
THEPOP.OFF
PRES.
WHAT
SURE
ANDHOWD0 YOUD0 lT?lf you set the pop-offpresyoumakethemotorrunleaner,
if youmakethepop-0ff
sure
pressure
youmakethemotorrunricher.In short,thehigher
A superstockerwaitingfor Sunday
or a Saturday
nrghtout.
pressure
lhepop-off
thelessfuelyouletintothewetsideof
ihecarb,thelowerthepop-off
themorefuelyoulet intothe
uetsideof thecarb.
Nowraising
withthe
or lowering
thefulcrum
armmesses
lemand
actionmorethanit doeswiththepop-off
draohragm
)ressure
andthat'sa wholenotherbucketof worms.Soto
nakeit simplefor yousetthe armheightwhereit is about
/2 bladeup fromthe baseof thecarbbody.Nowcutthe
pringoffthatsetsunderthearmtrllyougetlt to pop-off
on
lbs.andholdon 6 lbs,lf youcuttoo muchof{thespring
thespringbecause
on'tstretch
it willgo backto itsoriginal
ettingon youin the race(nowyouknowwhyI saidget 6
orrngs).
Whenyoucutthespringoff putthecutendintothe
rringwell.At thrspointyoushouldreshape
the endof the
tringbackto flatby hand.I neverleta carboutof my shop
69
wffiIlolson,@.9.4\.
ffiWe€DlgGD@
years
karters
0ver
fhe past
Irve
tried
keep
the
advised
with
to
the
needed
infornation
to
keep
up vith
never-ending
changes
in
the
Engine
Technology.
As
this
technology
change
so
do
on engines
the demands on
carburetion.
production
The HL-348C didn't
cone into
because
I santed
to se11 the
Karter
new'carb.
another
It
was Just
one of those
things
had to be
that
done to nake racing
better
for
vlth
everyone
and
to
stay
current
todays
engines
and classes.
Let's
back up a fev years
and shov you how and why these
changea
are
needed.
yeqrs
Back
when
a few
ago
I
deslgned
HL-348A,
the
Boon
the
"Big
C1ass"
Tas
Limited
Modified
the
90% of
Class.
In
short,
all
HL-348
Tillotson
were going
on Llmiteds.
Carburetors
yas
Since
this
the class
rrith
the highest
denand for
carburetora,
I
designed
the HL-348A
to fill
the
needs
vith
of
this
class
very
llttle
or
pop-off
no vorlr
needed
to
the
carb
other
and setting
than
checklng
the
pressure.
is
It
also
designed
so
that
the
Engine
Builders
had the roon
needed to Blueprint
it
their
to fit
way of building
a motor.
Was there
a problen
vlth
this
carb?
I
have
to
answer
this
rith
a
yes and a no.
The
Stock
rras starbing
Super
Class
shor
up nore
to
and nore
everl'
ueekend.
Nolr the super
drivers
Rohn Moon,
like
Scottie
and others
eagle
didnrt
a problem.
have
fn short
these
types
of drivers
are
the
best
of
perfect
the best
and they
will
flnd
the
spot
in the carb
that
ci11
tune
pover
out and make the best
no natter
how thin
the
tune
line
But the
is.
problen
najor
1s
that
Super
the
Stock
Class,
the most part,
for
ls nade
up of
dr ivers
thab
have
u
e
t
o
u
t
c
o
t
n
e
o
f
B
o
x
S
t
o
c
k
R
a
c
i
n
g
a
n
d
they
J
havenrt
had any hands on experlence
rith
a Tillotson
Carburetor.
As
I have already
statedr
the HL-348A was designed
to
fit
the
needs
of a Llrnited
Modtfied
better
than
a Super
Stock,
Bottom
line:
the HLjust
348A lras
you
a touch
on the top end and
rich
had
a very
slln
fuel
curve
to vork
vith
for
a Super Stock.
grovth
As the
Super
Class
Stock
started
it's
rate,
I kner
I had to
do something
to nake the tlllotson
HL-348
fit
closer
to
their
needs but
aU the
sarne time
not
ki11
the
carburetor
shere
it
vouldn't
uork
for
a
Linited
Modified.
This
HL-3488
brought
out
the
series
of Tillotson
Carburetors.
With
pattern
this
carb,
I tlghtened
up the dril1
a touch
and
had
an
E.C.
S/S
put
High
Side
Needle
in the carb.
This
toolr the expenses
off
the karter
to buy a special
Hi-Side
Needle
so
he
sould
have a vider
tunlng
curve
to
work
with.
This
ner
Hi-Side
Needle
also
worked
for
a Liurlted
uith
a
change rnaile to the Hi-Side
Needle
Seat.
part
just
The
last
1992
of
the
Season
the
Super
Stock
Class
sky
rocketed.
I.Ihy the
increased
build
up of
this
class?
Sirnple.
Racers
go faster
want
to
but
some donrt
vant
the price(y)
cost
of a good Linited
Modified.
With
the
boom of
ported
Super
Stocks
W.K.A.
also
vent
to
blocks.
All
changes
these
at the end of the
L992 Season made
it
vhere
50% of
going
the new carbs
$ere
to
going
Super
Stocks
and
the rest
to Limiteds.
70
t
7
I
c
!
(
I
t
T
b
a
s
r
t
a
b
a
b
h
f
v
b
c
n
t
I
2
3
4
5
6
7
I
9
jar
DragAnoUher
bee
into
honey
uas
the
N.H.R.A.
Jr.
thronn
the
ster
Classes
and
They had found
that
the
Racers.
Midget
Q.M.A.
Quarter
Tillotson
Carburetors
u
s
e
.
were the doninating
carburetor
to
and
Now yourre
sfarting
my problen
and hon time
to get
a picture
of
h
a
d
technology
backed
me up against
the ral1.
Now let I s
Super
Stockr
Okay !
add
up.
then
all
We have Karting:
Limited
Modifiedr
Modified
h
a
v
e one
Dragster
ve
Briggs
and Opens.
fn Jr.
(
2
)
Open Class
and
M
i
d
g
e
t
s
A
a
n
d
l/2
have tuo
classes,
Double
Quarter
Midgets
Uhat
use
the
HL-348
i
s
a
t
o
t
a
l
o
f
e
i
g
ht
That
Ttllotson
Carbs.
(8 ) classes
that
use the HL-348
Carbs.
just
You
say "No Problen"
fits
one
off
the
urake a carb
each
that
p
u
ll
she1f.
I
t
o
could
do
it
but
w
o
u
l
d
h
a
v
e
k
n
o
c
k
o
v
e
r
F
o
r
t
K
n
o
x
f
to
I
p
r
o
d
u
c
t
i
o
n
off
because
l
i
n
e
that
one
c
a
n
a
t
a
r
t
u
p
f
t
the
Tillotson
uiLhout
a truck
of carburetors
load
of one kind
r
n
a
d
e
.
being
problen
The other
leading
engine
I face
is todays
technology.
Every
builder
has
his
o$n
rray of
wanting
his
engine.
In
a carburetor
to fit
pattern
going
you
put
short r Do natter
rrhat drill
he
it
in
is
to change
somewhere
and
needs
a carburetor
Nou you
see
that
he can do that
cith.
rhy nay hair
is
long
and gray.
What uas the
ansner
to
all
of
the
above problems?
I had to change
the
HL-348
one more tine
and design
vould
fi 1l
it
to be
a baseline
that
pu11
al1
racing
needs
the
for
all
a helnet
on
and
sit
racers
that
betrreen f our wheels.
years,
after
At long
lasU,
a1l
these
the picture
has cone to a final
draving.
tr0ff
To nake
suitable
a carburetor
for
all
the needs of todayrs
the
fits
a1l"
is
shelf
noU only
impractical
but
impossible.
So vhat
had to
yas
go to the data
be done
sheets
and figure
out
vhich
class
of
racing
had
to
have
the
leanest
carbs
then
build
fron
there.
Here
are
the
findings.
Super Stocks r Limiteds
and
Jr.
Dragsters
need
a carb
is
today
that
putting
very
on
the
top
end
but
lean
capable
of
lots
fuel
of
in
the
you
At
you
boLton
to run fasb.
the
sane
time
have to have a carburetor
can tune
rrithout
hairline
adjustnents
for
Entry
Level
Racers.
As Rudy Wade said
to rne "Build
us a convertible
se
sith
so
can
ride
the top up or dovn".
I get
over
this
mountain
So how did
of probleurs
and out of turn
four
vithout
killing
myself?
this
vay I hope.
- Stage Left:
Exit
Right
Reneurber f stated
that
Engine
Builders
have
their
own vay and
they
pattern
need
the
dri1l
and
so
do
95% of
the
racers
that
do
their
ovn
anymore.
thing
product ion
The
HL-34 8C now cornes in
form
fron
TilIotson
vittr
the
following
dr i 11 pattern:
TILLOTSON
.875'
I
2
4
b
I
I
HL-348C
Yenturl
Seat
High Speed Needle
Seat
Low Speed Needle
Pickoff
Speed Fuel
Idle
Idle
Jet
TransiLion
Jet
Premix
Orifice
Air
Seat
VaIve
Fuel
fnlet
(
N
o
zzle)
High Speed Jet
P
i
c
koff
S
p
e
e
d
F
u
e
l
High
PBODUCTION HETEANOL (ALf,T)
vlth
l.00Or
Tbrottle
CABBUNETON
Shutter
.O62
.076
SLOT
.040
. o52
.042
.0gg+, A.B.
. L25 ALky
SLOT
^'KEEPS
YAo*IIlllHg
71
To take
the expense
ovn thing
off
the karter
that
vants
to do hie
ve
HL-348C
ship
the
Carb
the
Racer,
Dealer
or
Dlstributor
cith
to
a
plug
Sheet
fuel
r€11.
Blueprint
and a soft
for
the 1ou side
(5)
The Blueprlnt
Sheet
vlth
each HL-348C has flve
that
is
supplied
popular
different
blueprlnts
use
on
ib to fit
classes
that
the
the nost
HL-348C Serles
Modified,
L/4
Carburetor.
They
are:
Super Stockr
Liurited
Midget I Jr.
Dragater
and Modlfled
Briggs.
Nov letrs
look
at the blueprlnt
t-ry and fill
the
sheet.
in all
fr11
your
need s
fit
to
type
fron
of racing
and explain
this
to you the options
you can do to custon
sheet
and vhat
set
up your
HL-348C.
(vhich
Nor for
my wallc on yater
have
it's
staying
I
nastered
the
);
under
for
30 minutes
and coming
up that
on.
I still
have to vork
Okay nou is as good a tine
as any to lay
down,
to the little
this
9o
boys room (donrt
put
forget
dorn),
hands and rald
to
the
seat
wash your
the
ice
box.
j ust
Oh I
about
forgot
something
very
inportant.
On sone
snall
tracks
or heavy
class
Super Stoclcs (1ike
rith
Champ Karts
Super Stocks
in
prefer
then)
are
racers
tbere
sone
and
engine
still
builders
that
the
older
style
Tillotson
Carb
body,
like
Tas
built
the
HL-314
out
of.
Anyvay,
the nolds
fhat
nade
carbs
those
have
been
replaced
because
the
yere
parts
old
nolds
had so nany niles
on then
coming
that
the
out
very
rough.
This
type
body is nhat
of
re use to make 2/ Cycle
Carbs
and .875
Gas Carbs
for
Modlfled
and B Modified
Midgets.
Quarter
ye
These new I'Super Clean Bodies"
are
nor
stock
and
in
can
supply
tnem
in
Kit
Forrn to anyone that
needs then.
Part
You can
#HL-304A8.
patterns
uae any of the
folloring
drill
for
it
the HL-348C to set
up for
your
Alky
you vant
and to fit
race
traclr
needs,
if
style
of carb.
this
Nor letrs
turn
our attention
baek to the HL-348C.
Look
at
the
schematic
vith
and
re
vi11
start
on
draving.
the
#1
just
Remenber
back
aways
I
said
that
about
everyone
vants
to do his
oyn
you
thing
and
for
sure
the
engine
builders.
Before
ever
b.reak
out
a
drill
bit
vrite
easier
this
at the top of the book "Itrs
alvays
to nake a
f uel
hole
bigger
but
it I s Hell
to make it
snallerrr.
Back to Hole
on
the
draring.
*1
This
is the High Speed Needle
Seat
and feeds
the fuel
needed past
the needle
taper
cone
and through
the Hlgh
Side
Nozzle.
designed
I
the carb
to cone with
thls
hole
.062 to lean
at
out the
top end of the carburetor.
The
n
e
e
d
l
e
t
h
a
t
c
ones
in the
"stock"
HL-348C is an Ec-015
long
sensitive
taper
for
tuning
control
on
the Hlgh
perfect
Side Needle
hole
and yorks
for
all
classes.
For the early
HL-3488,
this
EC-015 uas a speciai
needle
for
the High
you can order.
Side
that
It
also
rill
be a big
edge
for
cleaner
tuntng
on all
fron
carbs
HL-314
thru
the HL-3488,
except
for
the the
HL-293.
HL(3)
336
and
HL-348A.
These three
unit6
a special
all
take
Conen
"Blg
High Slde Needle.
The EC-015 High Side Needle
sill
also
work
ve11 in all
the 2/eycte
HL Serles
Carbs
for
cleaner
tunlng.
I{e will
cone
back
to
more on this
needle
in a moment.
Again
back to Hole #1 - The High Side
Needle
Seat
is
at
.062.
I rve
been
dovn
up
and
this
enough to rear
ladder
a1l
the palnt
off
the rungs
and
it
cones
A 2/CycLe
down to this:
Stock
or
Stock
Appearing
on Gasi
4/CycLe
,tr. Dragster
Super
Stocks,
and
sone
Liniteds
have
to
have
the
fuel
poyer
cut
here
off
to
nake
killer
clean
on the top end.
Now before
I go any further
on this
hole
and the changes
that
can be nade,
f have to
stray
over
to
the
Hiqh
Side
Nozzle
and
cover
flrst
it
becauae
1t ul11
affect
what you do or donrt
do vith
the
.062 needle
seat.
The High Side NozzIe,
you
dunp
tube
or
whatever
call
1t (tne
brase
ridget
hanging
down out
of
the top of the carb),
in stock
forn
1s
,432
long.
also
It
has
a ball
the
in
end
1t
of
t,hats
in
the
fuel
strean.
This
ball
rorks
as
a check
valve
put
for
baclc"
and
in
there
by
"blow
Tilfotson
gas
for
motors.
On a cas
notor
it
helps
to lean
out
the top
72
th16
ball
ln there.
Carb ve donrt
need or vant
on an Alky
you
nouth
the
into
the
of
Wlth
a llttle
can
reach
screvdriver
pop
fa11
out.
the
little
This
v111 1et the ball
and
c11p out.
catburetor
you k1ller
give
you leave
torque
tt
111l
nozzLe at nax length
thls
Nov if
vay.
The dorn side
of
of
turns.
In
shortr
it's
real
rlch
thle
off
the
end
motor
top
of
the
nozzLe
being
this
long
it
nakes
the
ls
alBo
the
get on the
enough
you donrt
long
But on short,
top
short
tracks
rlcher.
problen
is bhab you
long
other
rlth
this
The
it
belng
to go dead rich.
you get
fn
short,
the
shorter
do hurt
the capabilities
of nax air
f1ow.
you get rith
vacuum
slgnal
naking
more
air
air
the
nozzLe,
the
flou
less
getr
it
1s.
fuel
it
the
leaner
on the vet
side
to pull
out.
The
shorter
slgnal.
balance
here on this
verses
fuel
flos
There
is a fine
line
length
does not rnean
re refer
thie
Although
to
aa
Slde
Nozzle"
this
the
"High
nothing
it
speeds.
that
cones
through
at lor
gray
needs covered.
Thls
brings
up another
area uhat
or
in
a real
tlght
At
engine
speedsr
the start
break
low
like
off
y€
back
out
have
do get
out
of the High Side
turn r
to
and
fuel
total
up R.P.M. rs.
Nozzle
to pick
out
englne
for
At lov
R.P.M.rs,
70?6 of the fuel
the engine
is coning
and 30* of the fuel
needs are being
taken
care
of
the Lor Side Needle
of
port.
off
the High Sloe Nozzle
and the throttle
ie 1n the side
As the notor
Btarts
to gain
R.P.M.rs
position
fuel
balance
starts
change
as
alr
speed
open
this
to
the
the venturl
This
vorks
Ilke
a teter
increases
through
of the carburetor.
out of
and changes
to a point
vhere
re have 30% of the fuel
coming
totter
yell
and 7O?t of the Htgh Side
Nou you
can
see
the Lor
Side
fuel
nozzle.
of
length
that
hor ue can affect
the
fuel
balance
the
carburetor
by the
ve nake the High Side Nozzle.
ye
Nozzle,
To change
the length
of the High Slde
have
to
remove
it
you
carburetor
body.
To renove
the
nozzLe
is no big
if
fron
the
trick
steps
to follor.
knoY the
Needles.
The first
thing
to do 1s
to
remove
the
High
and
Low Side
not
danage
so 1t's
in the ray and the High Side
ao you
vonrt
The Lov Side
carb
body.
This
a ruet
because
or the
is
the
needle'
rhen
the needle
(2)
part
out or even at tvo
bottoned
turns
outr
has
stuck
of the tip
lnto
(trench)
side
feeder
hole
nozzLe
tnat
feeds
into
the
for
the
fuel
nozzLe
and air
trip
lnto
the venturi
strean.
lts
you havenrt
Trench
in the nozzLe?
rord
it?
A ney
that
heardr
isn't
TIBIICE nozzLe
in a vhile.
More on this
good a time
The next
step
is to renove
the punp stacks
and nor
1s
as
t
h
e
a
r
n
.
as any to remove
inlet
needle
and
Take
not
to
the
care
lose
junping
pop-off
spring
that
the arm.
is under
It
has
a habit
and
of
up
auay and getting
lost.
running
ye
point,
your
At
this
nou
have
carb
body
strlpped
dorn.
Both
p
u
m
p
a
nd
needles
out ,
stack
renoved
fulcrum
arm,
needle
and
spr ing
your
The
next
step
is
to take
and hold
renoved.
the carb
body
ln
hand
(preferably
y
o
u
d
o
n
r
t
r
r
l
t
e
the
hand
rith)
and rith
a scribe
inslde
reach
a line
around
of
the
venturi
and scribe
the
nozzLe
vhere
it
is
exposed
you have this
good so
the
carb
body.
Make sure
and
touches
scribe
line
you can see rhere
it
is,
at a tater
date.
top
Loolc at the carb
body from
the
side
and you can aee the top
end
y
o
u
High Side Brass
l{hat
of the
NozzIe.
see there
appear6
to
be a screwnotch
it'B
not.
driver
cut
into
it,
blt
f
repeat
this
is not
a screuI
driver
notch.
ft
s
for
LIXE
UP PUIPOSES OILIr
rhich
ue
ri11
come
to
later.
jet
You youldn I t
believe
hor
nany racers
have tr.ied
to screu
this
you
r
i
t
h
a
s
c
r
e
r
d
r
i
v
e
r
b
y
t
u
r
n
i
n
g
out
iU.
This
is
understandable
$hen
don I t lrnon and that I s lehy the time
is spent
here
on thls
You I re
subj ect.
not a carburetion
technician
but by the tine
ve get done you vl11
have a
end
but
73
good
rhat,
your
have
a norking
knowledge
of
and
understanding
of
Tillotson
your
needs.
hov and yhy you are doing
it
to fit
raclng
body.
The
fron
carb
the
Okay,
nor uerre
ready
to remove the nozzle
(snalter
nozzl.e)
and placlng
by
a pin
than
the
ray
ve
do
this
is
taking
and
inside
of
out
to the
on top and tapping
the nozzJ-e ti11
it
falls
it
body.
the carb
hole
for
the
nozzLe
with
nozzLe
out you can see that
feeder
the
the
top
of
the \ozzLe.
You
is 90o off
fron
line
up
notch
the
the
cut
inbo
you screred
Side Needle
in
left
the
High
can also
if
up and
see nor that
and
of the needle
rchen you
out
nozzLe you sould
tapped
the
danage the tip
put
up the side
one hell
of a score
of the nozzLe.
your
you have the nozzLe
letrs
look
at
hand,
Nov
that
and
in
out
band of your
types
and what they
due to effect
the pover
carb.
lengbhsr
indoor
or
If
all
of your
racing
like
1s done on smal1 tight
tracks r
you take
bar and
the spray
600 feet
and less,
then
f vould
reconrnend thab
groove
snap
ring
cut
it
off
to
.400 long.
Th16 would be Just
vhere
the
disappears.
This
done
in a lathe.
0nce you have the
operation
1s best
post
and
nachine
nozzle
end nachined
off t turn
angle
the
the tool
on an
you have no tather
scribe
can
also
be
on an angle
to your
this
1ine.
If
and
the
end
rith
a file
done by putting
shaping
the
nozzl-e in
a drill
i
(rire
the
print).
t
l
t
t
t
I
I
I
t
H
o
!l
H I . S I D EN O Z Z L E
b
t
b
.400
to
.325
Scribe
Line
II
I
Cut Angle
P
b
f
s
I
I
I
youo
for
nozzle
nax
does
tvo
Onet
It
leaves
the
at
This
thing
puts
fuel
the angle
on it,
length
for
a rich
flow.
Tro:
By putting
this
nozzLe
the part
of the
that
sticks
into
the alr
strean,
a pencil
tlp
lilce
possible
you the best
air
flov
by it.
and gives
on
the
Blueprint
Sheet
it
saya Xf, (vhlch
for
make)
.375
Nor
stands
1ong.
This
is
the best
middle
length
for
Super Stocks.
of the stream
polnt
a tine
This
is as good
as
any
to
bring
this
to
vlev.
As a
( one
general
a Sprint
Motor
rule
of
thumb,
that
has
to
on a track
run
with
a lot
of
tight
left
and
hand
right
turns ) nas
to
have
a rlcher
Dirt
Tracks
runnlng
carb
than
a motor
for
or Street
Races.
you can
Stock
On a Super
shorten
the nozzLe up to the mlnunun
length
but
of
.325
for
Dirt
Tracks
due to the lack
nozzLe
of signal
on
the
at
this
torque
6r500
R.P.M. rs
will
lengt.h,
under
suf f er
a bunch.
Yes, on
some dirt
tracks
this
is the faster
vay due
to
the
superior
alr
flov
of
the HL- 34 8 C.
How much air
do you need?
Good question.
I can,t
ansver
one.
that
But the carn vhich
has to nake
tech
Box
for
Stock
say6
as nuch as a
"Not
Linited
Camf'.
Can you
make different
nozzlea
length
and change
for
different
them
types
your
of tracks?
Yor.l bet,
This
is
flne
line
the
tuning
carb
for
possible.
fastest
combination
you
what
lengths
do
nake?
.375,
.350
and
.325
Nos thls
long.
length
is
fron
the
top of the nozzLe
to the bottom
and anything
that you
get
cut
off
to
these
lengths
cones
off
the
open
of
the
nozzLe.
end
Alrays
cut
on an angle
the sides
to inprove
air
flov.
74
a
v
p
E
I
sonevhere
Back
up
at
the
start,
f nentioned
a nozzLe
rith
a TEEXCE
around
1t.
Let I s cover
that
Doyr
On a Di rt
Track r Super Stock
you
or
Limi ted r
nozzLe
thi s
can
buy
sone
track
times.
This
nozzLe
s
h
o
r
t
t
o
s
t
a
r
t
v
i
b
h
is
vhlch
makes
it
leaner
you
and the
design
of
it
nakes
it
leaner
also.
All
have bo do
rith
this
one is pop the ball
out and check
holesr
Uhe feeder
uraking sure
they are
.062
in s i ze.
nozzLe
This
has
a band
cut
around
outside
of it
the
that
the
fuel
(2)
travels
around.
There
are tvo
holes
drilled
in this
band to let
the
go fron
fuel
the band into
the fuel
hote
that
leads
into
the
air
strean.
Yes this
can and
sonetimes
is
vinner
the
trick
the
up front
has on you.
you
have
If
a Super
Stock,
LLmited
,
I
r
.
D
r
a
g
a
t
e
r
or
that
runs
too
rich
on
the
top
end
you do,
no natter
what
is a possibifity
there
that
your
this
rtozzJ-e vi11
problen.
cure
use
f
this
nozzLe
a lot
rhere
the
High Side Needle
hole
has been nade too large
needs.
for
a Super Stocks
Surrary
on l{ozzlea:
The longer
the
nozzLe
the
richer
it
1s and the
shorter
the
nozzLe
the
leaner
it
is.
you have
If
a carb
shere
the High Slde Needle
hole
has been drilled
or nade too biS
(farger
and the carb
alsays
runa
too
richr
cone)
a faUter
needle or a band nozzLe
your
problem.
could
help
Nor
let I s put
your
the
High
Side
Nozzle
back into
carb.
We put
it
back like
ne tootr tt
out r by
tapping
it
back
into
the
hole.
Mat<e sure
you
that
have
the
cross
feed
holee
lined
up over
the High
Side
Needle
hole.
Also
use
sonething
soft
to lay
on top of the
nozzle
to tap on vhen
puttlng
j ob
the
nozzle
good
back
in.
A wooden dorel
rorks
for
the
at
hand.
Tap
in ti11
the
top of the nozzLe
ls flush
ryith
the carbs
wet side
f loor.
Let I s nove our abtention
the
to
+1 HoIe
on
the
schenatic.
For
a
yith
Super
,tr.
Sbock
or
Dragster
you start
I
advise
that
off
this
fuel
inlet
hole
at the
.O62
size
you can alrays
to start
vith.
In ehort,
nake
1t bigger
but
itIs
He1l. to make this
one smaller.
you change
This
1s the very
last
hole
the
size
on.
Start
it
at
.O62
,'as you
uhere
I
have
it
at.
A general
rute
of
here
thumb
rould
be
shorten
the
nozzLe
for
more air
flow
a leaner
and
top
end this
can give
you the option
of bringing
up the High Side Needle
hole
to
1et
more
fuel
past the needle
to
fill
the
urotors
needs
at lower
R.P.M. I s and lean
out
Dore on
the
top end due to the loyer
pulls
signal
that
fuel
out
the
of
ret
side of the earburetor,,
Are you confused or lost
Letrs
it this
try
?ay.
yet?
I
an!
On the
race
track
you
at
racing
speeds
vanb your
mobor to hold
at
300o to
3250 notor
tenperature
and your
High
Side
Needle
out
1 to I l/4
turns.
getting
This
vay
if
heat
starts
you
to the engine
can
rlchen
1t
up sone to cool
pover
it
off.
ff
top
end
you have roon
is a bit
short,
to lean
it
a bit
out
by turning
in the High Side Needle.
you have nade the declsion
Let's
assurne that
your
on
Super
Stock
or
go
Limited
vith
to
a.350
overall
length
spray
bar for
more air
and
flor
you find
you have to be nore
that
than
L l/2
turns
out on the High Side
Needle
to
keep
the notor
cool
or have good pover
in the nid-range.
This
you to step
also
vould
be a good
sign
for
up the High Side Needle
hole
a
bit.
If
it
Yas D€r I rould
only
nake these
changes
.002 at a tine.
Thls
go too
vay you donrt
far
too
fast.
The
tos
Side
Needle
in bhe HL-348C is the sane needle
has been
that
years
used
for
as
the
Lov and
High
Side
Needles
for
most
Alky
carbs.
you have an older
Botton
line
here
is
if
you
series
ALky Tilfotson
carb
can take
the needle
out
of
it
and put
it
in the High Side NeedIe
hole
of
'Cil Carb and test
your
you find
it.
If
bhe
blunt
needle
is
the
fastest
Yay you can nake your
Hiqh Side Needle
tip
like
the Low Side vith
a fes
75
strokes
of a file.
You can also
fatten
up the
top
end
rlthout
changlng
hole
the needle
by
blunting
the
tip
on
the
Hlgh
Needle
a touch.
In
sLze
Side
shortr
yourre
you
sone
of
the needle
hole.
taking
tip
nass out of the needle
If
you
the
Low Side
lay
High
and
Needles
side
by side
will
see
the
that
but,
taper
ls
the
sane
the
has
Low Side
Needle
a blunt
tip.
The Htgh
has had this
Side Needle
taper
carried
out
to
a sharp
tip
and is longer
easier
so you can flnd
it
at racing
speeds.
you
You
can
nov
see
that
there
are a lot
that
can
of courbinations
golng
passage
vork
vittr,
fron
leaner
richer
on this
High Side
fuel
to
to
part,
Keep in nind
the engine.
today I s rinning
engines
for
the
nost
due
porting,
to
cans and type
of tracks
a carburetor
that
is rlch
on the
like
you
bottom
side.
This
in turn
relates
directly
the
Higtr Side because
to
g
o
i
n
g
alrays
have
that
30% of fuel
flow
at
louer
R.P.M. rs
into
the motor
fron
the High Side Needle
and Nozzle.
we can noy turn
our attentlon
and 6.
to #3r 9r 2,4.5
.
Nunbers
3 and
9
in
the
off
holes"
and
older
days vere
called
"pick
years,
fed the fuel
these
holes
to lbs
respective
needle.
In
the
early
youldntt
pass
it
Yas
found
that
these
snaller
feeder
holes
to the needles
the volune
of fuel
needed to
having
needles
to
keep
flat
spots
the
from
in the
turns.
Botton
a flat
spot
line:
is due to being
too
lean.
So the
tee-slot
was born.
good
As racers
think
big
bigger
is
bett€f
is
so
carbs
then
" r
" if
nere
hacked
and cut
on a lot.
(ffat
problen
When Tillotson
ras
lnformed
spot)
of this
tney
changed
p
i
c
k
(2)
p
o
r
t
nolds
of fuel
the
fron
the
off
type
to tyo
open s1ots.
0ne
each needle.
for
This
nev design
is
used
all
HL Serles
ln
the
Infinite
and noH the nev HL-1A Carb.
Radius
Carbs
you
Yesr
these
slots
are Dore than
atl
adequate
fo handle
the
fuel
b
u
t
h
a
b
i
t
s
a
r
e
need
old
hard
to break
and most engine
buitders
still
feel
more confortable
sith
a tee-slot.
j oin
your
you're
going
If
carb,
High
and
to tee-slot
the
Lov
Side
slots
vlth
a
t/8t'
Ball
End Mi11.
Donrt
use a mi11 any bigger
this
than
you
may cut
because
into
the
radius
that
leads
into
the
needle
hole
itself.
This
radius
that
leads
into
the needle
hole
is
inportant
to
the
passages
fuel
flor
into
the
needle
hole
and
doesn I t
like
belng
nessed
rlth.
When j oining
pockets
go
the High and Lov Side fuel
together
don I t
r
(not
y
o
u
y
o
u
deep
too
as deep aa the pockets
are casted).
If
do
ri11
cut
bo the outside
and have one heck of a leaker
of the carb
on your
hands.
Once
the
tvo
slota
are j oined
rith
each
other r
coll€
the
niddle
up
with
a
l/4 "
urill
and J oin
end
the needle
and aeat
cavity
vith
the
High
and Lov Side
channel.
Let'e
turn
our attentlon
to Holes
4,5
and 6.
*2r
Holes
4, 5 and
ports
Lory Slde
6 are
the
feeder
and get
their
fuel
plug,
fron
the
fuel
well
that
is covered
by the welch
better
knosn as the
you have to remove
Lor
slde
Soft
Plug.
To get
to these
holes
soft
this
p1ug.
When the carburetor
vas
p
l
u
g
bu11t,
this
uas put
ln and the center
vas pressed
dovn to tighten
up the plug
in the urachined
recess
for
it.
you
put
To renove
thi s plug
have
to
a hole
in
the
middle
it
of
first.
plug
The dlstance
from
the
under
side
of this
soft
to the bottou
of
the
fuel
sel1
is
very
close.
In
shortr
lt's
very
easy
to
drill
plug
through
the
soft
and the bottom
of the
fuel
at the
re11
sane tlne.
j ust
you
you
Needless
your
to
say
if
do this
have
ruined
nefl HL-348C
Carburetor.
To put this
hole
in,
it
is best
to do 1t with
a 3/16
flat
botton
end
m111 and a m111ing
urachine.
This
uay
with
you car
the
flat
bottorn nlll
just
plug
cut
through
the top of the soft
you
and
stop.
If
donrt
have
the luxury
of ovning
a nilling
nachine
you
or have a buddy that
has one,
76
I
I
I
I
1
I
p
e
u
n
t
a
t
i
t
p
a
p
just
ground
can nake this
hole
rith
a t/8"
dr111 bib
Thls
on 15o.
rill
getting
nake it
sithout
the botton
of the fuel
rell.
Once you have the hole
plug
you
in
tbe
center
of
soft
the
can nov
take a cotter
key pu1ler
and hook the bip
into
the hoIe.
With
a trist
of
plug
the vrist
the
soft
v111 pop out.
plug
Wlth
the
you
(3)
soft
out
can
the
see
top
side
of
the three
holes
nunbered
4, 5 and 6 vhich
in turn
are
by
Low Side
fed
the
Needle
hole *2.
Before
ve start
changlng
the size
of these
hoIes,
re need to have
an
understanding
that
of
their
function
is
in
the
operation
of
the
carburetor
and hon they
affect
each other.
EOLB t4
is the IDLB FUBL DISCEIIGE
POIT.
ls
rhat
ue
EOLB *5
call
the TBAI|SITIOI{ atBT and HOLB *6 is a PtA-ilII
OIIFICE.
just
Letrs
ports
nov
look
at
rhat
these
do and hov they
affect
the
pouer and function
of your
carburetor.
For years'
f have stated
you
in Tech Articles,
Tune
Sheets
etc.
that
don I t
ever
have
the
carbs
idle
screv
set
where
it
holds
the
throttle
shutter
open.
This
good
your
is
a ruat
for
operation
of
carb.
The
reason
for
all
of
you
this
ls
if
have the shutter
where it
cracked
is
enough so the notor
you
can
run,
then
have
an alr
bleed
over
the top of
jet
the
shutter.
This
air
coning
port,
in leans
out
the
idle
discharge
chlch
has a lot
of bad side
affects.
l.
You
don I t
vin
any
races
rittr
the notor
idling
in the pits.
y
o
u
p
u
n
p alky
What
do is
right
into
the oll.
go closed
2. If
the shutter
canrt
the motor
1s hard
to start.
go
3. If
you
the shutter
canrt
closed
v111
have
a flat
Bpot
1n
pocer
the
band nhen you lift
for
a turn
and through
the mid-range
due
to
a lean condi t i on.
Now refer
ports
to the
dlagram
on "Horr these
uorkrt.
l . , E TS I D E
BOTTOM
When the
all
shutter
is
the
vay
closed
this
1s
same thing
the
aa
putting
your
hand
over
the
end
of
the
carbr
dlnost.
In
short,
al1
(vacuun)
pumping
pulled
engine
force
port.
1s being
gives
on thls
This
rich
mixture
starting.
us a very
for
More
lnportantly
it
us a rich
9lves
left
nlxture
rrhen ue
our
foot
for
the
start
line
break,
llfting
for
a
or lifting
to
set
up for
a pass on the race
turn
track.
ve need
In short,
as rich
a fuel
nixture
as possible
for
torque
at these
tlmes.
positlon,
When the
1n this
shutter
is
closed
air
is
coning
through
j et
pre-nix
port
air
the
and
port.
bhe
transitlon
The air
nixed
being
port
into
the
Idle
discharge
nakes
bhe
fuel
a conbustible
nixture.
Ag
j et
past
throttle
( see
the
shutter
suings
the
transltion
diagran)
this
goes
port
hole
port
fron
being
an
air
mlx
port
to a fu11
fuel
dlscharge
and supplies
the
fuel
needed to pu11 up through
part
the
mid-range
of the
poner band.
77
presaure
yes
pop-off
affects
Nor
Track,
knou,
on
a Sprint
f
the
punp
you use.
so
does
the
Thls
re vi11
cover
carburetor
and
fuel
later
you
an
Walbro
now ve
vl 1l
have
E. C.
but r
for
relate
to the point
that
presaure
at I L/2 pounds.
Hlgh Volune
Fuel
is set
Pump and the pop-off
porbsr
Back
and this
5 and 6.
The
to
the carb
series
of fuel
*2,4t
(*Z'1 is
Lov Side Needle
hole
hole
size
right
size.
Donrt
the
change this
weight
and
altltude
for
a Super
Due to the type
class
Stock.
of track,
c11l
dictate
vhat
Te do fron
here on out.
your
private
When you get
area
and you
to
lhe
race
track
test
or
parade
you have a flat
at
find
that
spot
on
bhe
vhen you stand
throbtle
porting
1ap
speed,
this
r*ould
can,
and header
indicate
that
due to your
conbination,
the
engine
wants
a rtcher
carb
(nore
fuel
off
the
botton)
point
At this
I
This
have the High
at
l/2
turns
out
Side
Needle
probably
sill
not
be
too nuch for
noy this
is
the
the top end but
right
problem
at hand because
ue are rorking
side.
on the botton
get
you
Cone out
on
the
Los
Side
to 2 L/ 2 turns
out.
Needle
untll
point
gb
pull
good
If
at this
the carburetor
end then
will
off
the bottour
on up
to
the
upper
end
of the poyer
out
is nore
band.
Yesr 2 l/ 2 turns
than rhat
ve want but
for
nov ltrs
okay.
Once you reach
the max R.P.M.
motorr
6,500
to 7 ,2OO r dnd the
of
the
notor
off,
is
out
shuts
this
is te111ng
ua that
the High Side Needle
too
far
has become too rich
and the motor
to lrake pover
or run.
Now take
it
in
L/4
of
a turn
and see tf
takes
of the
that
care
rlch
go 1n another
condiditon.
If
it
doesnrtr
L/4 of a turn.
Now yourre
at 1 turn
out
and vhere
re
to
be
for
that
needle.
want
This
w
e
is ao
have sone tune
left
for
race
time.
Letrs
say
that
the motor
a touch
runs
clean
here
but Juet
shors
rlch
still.
it
sants
to
In shcfrtr
shut
off
or
feel6
flat.
So werll
take
the
Low Side
ln sone and 1t clears
up (remember
30* of the fuel
is
coning
out
of the Low Side
fuel
vell
at f,ull
throttle),
but you knos that
as soon as
you slor
p
a
r
a
d
e
y
o
u
'
r
e
g
o
l
n
g
down to
lap
speed
to
have
a flat
spot.
Nor
yourre
get
you do and danned tf
you
starting
to
caught
up in a danned if
donrt
eituation.
you
is telllng
What )rour carb
is
that
1t's
too
off
lean
the botton
pattern.
point
and
it's
time
to
change
the drill
At this
I
vould
nake
tvo changes.
go
I
vould
max out
First
Hole
anil
+4
to
the
.043 size.
r
Under sone very
rare
conditions
I've
sreen vhere
this
has
+4 hole
had
to
go to .046.
go
Nor
nove
Hole
to
Tal(e thi E hole
#5.
to
.054.
In short,
don't
y
e
t
.
g
o
all
the rray vith
Put
the
it
carb
back
together
and
baclc to the
(2)
you
you still
track.
If
find
have to be out more than
turns
on
tro
jet.
you stitl
the Lou Side Needle
need to cone up on the transitlon
yay up slosly
you trave tine,
work your
If
.OO2 at a tlne.
you
get
0n1y under
extrene
cond i t lons ,
vl 1l
ever
to
. 059.
I feel
j et
for
a Super
Stock
anythlng
over
.056 on the
transition
wllI
be too
nuch.
Whatrs
the
botton
llne?
You rant
bo rlnd
up vlth
one (1)
turn
out
on the High Side and I L/4 to L 3/4 nax on the Lon Slde.
you find
you have
go
plunb
If
that
to
up to rnax (.059)
on the
tranj et
get
sitlon
off
to
the turn
or start
breatr vithout
line
a flat
spot
and the High Side
Needle
is
3/4
or 1e6s turns
out off
the
seab,
then nor
and only
noy,
step
up Hole #6 to help
lean
out
m
i
d
r
a
n
g
e
a
n
d
the
top end
you get fron
affect
that
the Loc Side
fuel
sell
at full
throttle.
t'nov you knotr rrhy f have gray
0ne rnore time
I ri11
state
hairtr.
go hand in hand for
Alf
these
steps
all
notors.
Only the
sizes
need
changing
to fit
the motor
size
or horseporer
level.
pressure,
Does the pop-off
fulcrum
alr
height,
type
and size
of the
needle
pattern
and set
affect
the dr111
of your
carb?
Yes,
it
does nuddy
WI
lr
p(
YE
th
ro
ln
rl
DA
ls
se
aa
Ca
Su
Re
ha
fu
e1
na
YE
78
t , / E TS I D E
a
AIR FLO}I
BOTTOM
Hole
is
+6
When the'throttle
pulled
ls
being
port.
sbi11
urixing
air
into
the fuel
supply
in the
fuel
(see diagran)
shutter
is
in
the ride
open position
port
out
of
the
idle
discharge
and the transitlon
well.
fuel
jet
t , I T TSI D E
R
AIR FLOII
BOTTOM
pre-nlx
The alr
putting
orifice
ls
stil1
air
into
the Lou Side
fuel
p
r
e
m
i
x
As you can see,
put
the air
orifice
is
an
in
on
angle
so
geu
it
can
more
outside
air
coning
into
the carb
and help
nake its
rnore ef f ective.
gains
As the engine
R.P.M. ' s and
the
air
flov
volune
and air
speed
lncreases,
more
pre-mix
air
1s
forced
port
up
thls
air
teaning
out
the
rich srlxture
coning
fron
the Low Side
fuel
we11.
There
should
be
sone light
conlng
on in the back corner
gray
of your
natter
and you can start
to understand
hov
port
critical
the size
of this
ie.
By now you can see that
a Super Stocks
needs are for
the
leaner
carb
settings.
you
The Blueprint
Sheet
that
your
received
vith
HL-348C,
shors
that
gets
as the notors
bigger
and nore pouerfullr
the rnore fuel
they
need.
For
a sanple
carbr
u€
ri11
stay
vith
the set
up for
a Super
Stock
Carb.
The vay f
have
t\e
Low Side"circuit
now ri11
work very
re11
for
the
Super
Stocks
on
a 1ot
of
the
tracks
that
are
at
higher
aftitudes.
you
go
Renenber
that
as
up
in
altltude,
for
part,
the nost
carburetlon
ha.s to
be
a touch
leaner.
Keep
this
yourre
in
mind
vhen
changing
the
( fuel
fuel
denands
of the carburetor
port
discharge
sizes ) .
Another
thing
that
needs
be
to
brought
up is fEvBne
IEVBX
use
an
electric
dril1
to
change
any
of
port
these
fuel
sizes.
Always
use
a
pin
yes,
nachinests
vise
to hold
the dri11
bit
needed
and
drill
by
hand.
pin
re have this
vise
and alL
the precision
drill
bits
needed
in Kib Forn.
vell.
that
role
79
picture,
up
the
This
unlt
sone
kind
is why
to
nake
this
cotne into
of
you have to york
6ane picture
and stay
frour sone set basellne
there.
for
arn
height.
That I s why
the
.065
to
.075 on your
fulcrun
This
glves
you the right
action
flft
of the needle.
For a rlcher'
on
bhe
rate
a leaner
carb
.065 and for
carb
.075.
pressure
or
a touch
for
The pop-off
is alvay6
at I l/ 2 pounds
lover
more fuel
or a touch
higher
for
fuel.
less
In the xElf EL-348C Serles
hole
brought
up
I have had the pulse
carbr
pulse
punp.
to l/8
Make
size
for
a stronger
sure
that
thie
the
nain
to
hole
is
lined
up perfectly
cith
hole
1n the nanifold,
the pulse
yas
plug
you noticed
When you renoved
on
the soft
sone
sealer
there
put
the
top of it.
Thls
is
a type
Tll1otson
there.
You
epoxy
that
of
put
really
don't
need it
so donrt
about
not
it
to
back
on.
uorry
having
put
plug
punch or
Just
the
back
drill,
in
and
flat
botton
rith
a snall
place
whatever,
plug
it
on
top of
carefully
a
the
soft
and
very
take
plug
snall
hanner
tap
and
the
ti11
it
flattens
and
top
of the soft
out
tightens
up in the hole.
job,
good
plates
As sith
any
Blueprlnt
all
take
and surface
on gla6Bi
(360 or 400 grit)
and sandpaper
they
flat.
Next
debur
alli
to assure
are
the
edges
so
the
fuel
flow
vlll
lts
be clean
as it
nakes
Yay through
the
passagerays
to the needle
and seat
assembly.
punp plates
When re-assernbling
the top
don I t overkill
the torque on
the screvs rhen you tighten
then.
What did I forget?
ODI' ANd BIfDS r
you have to
Fuel
Punp - 0n a Super Stock or Linited
motor
Modified
pumps signal
punpg
off of the lntake
nanlfold.
Nov the fuel
!let the fuel
position
pulling
signal
fron this
has the strongest
slgnal
in noU bloring
punp should
out.
geg lts
So thls
neans that
the
fuel
be deslgned
to
pulse port.
slgnal
fron this
yay to
punp?
Hos do you lcnov you have the
right
fuel
The easiest
p
u
n
p
find
look
out
iE to
at
the
closely.
an lntake
If 1t's
type
fuel
punpr
vill
have
then
it
a snall
hole
drilled
you can see or a little
brass
looking
rock
that
to
the
atnoaphere.
The
reason
for
this
vent
yeak
goes
closed
signal
is very
the
for
the
pump tha
top
in the
surge
a pressure
is also
relie
when the valv
is so that
pumps
to
return
back
for
next surge that vi11 pump fuel.
There
hand for
is
a helping
tt
by not
only havlng a vent
to t
atnosphere
it also
has a return
dlaphragm
spring
in it like
a Box Stocl
Brlggs carb.
punplng
In short,
thie punp has bullt-1n
insurance
for
I ts
cycle by being helped to return
for its
next punp cycle.
Another
punp as close
thlng
to
rernember is
to mount the
fuel
a8
possible
pulse
to the uranlfold
so the
wl11 be as strong
as possible.
The
shorter
get
the pulse tuber the stronger
you vltl
the signal
to
the
fuel
punp.
The following
steps
on nHow to Tune Your Tilfotson
Trackside,,
is the
j
g
e
t
best
Tay to
the
ob at
hand done.
vouldn't
ft
hurt
a thlng
t0
neno r Ize thi s .
their
TNACK TUIfII{G IOUB TILLOTSOI{:
( I )
Set
the
needles
one
turn
out on High Side and I l/4
out on Lor
p
o
s
l
t
i
o
n
.
Side for
a starting
Be sure
that
the
carburetor
idle
adjuetj ust
ment
screrr
is
vhere
it
plate
set
cuehions
the
throttle
rhen
tt
closes
but not
open
enough
ao
the notor
that
can idle.
Start
the engine
and nove
out
onto
the track.
Give the motor
a couple
of
to
easy
laps
Yarm up.
you are running
Be sure
in these
rarn
up laps
that
clean.
Nor
your notor
bring
donn to parade
lap
speed.
Accelerate
hard
as you rould
for
the start
you have a flat
break.
p
r
o
blen,
line
If
spot
or a bog
thie
could
be due to a lean
condition
on the Low Side Needle.
Cone out
L/8 of
80
a
c
t
p
t
t
c
t
t
N
f
a
c
c
o
N
n
B
I(
f
o
a
t
Y
t
on the Lon
a turn
Side
Needle.
conlng
out
Try
again.
Keep
on the Low
pul1s
the notor
ti11
vlth
no
bog or flat
spot.
Nor try
Side Needle
hard
sane
test
coning
off
the
Once you
are
the
the
turn.
satisfied
vith
performance
you
pu1ls
off
are
the bottom
and
notor
c1ean,
ready
to
the
attention
to the top end.
turn your
With
notor
the
under
fu11
run clean
all
the
vay
throttle
it
should
end
the
the
longesU
motor
to
of
straightaway.
the
shuts
off
then
If
you get
cornes back on by itself
before
to the
end
of the longest
straiShtavay
this
is nore
than
likely
due to the fact
that
the carburetor
is
set
on the High Side Needle.
too rich
is to take
the High Side
The
cure here
( lean
pull
Needle
in
out)
L/8
the
turn
increnents
ti11
the notor
clean
full
lengt,h
of the straightaway.
you
As you lean
in
the
High
Side
Needle
the best
top end pouer
for
yourself
good
are
also
leaning
out
the bottom
a touch.
assure
So to
of
corner
speed
no
you need to go back now and
and
flat
spot
of.f the botton
check for
this
one nore
tine.
can
of a Tillotson
As you
see,
the tuning
on a 4/Cyc1e
is a fine
balancing
line
betveen
and
Lou
Side
the High Side
pLus the pop-off
pressure
Needle adjustments
in the carb.
I{OTBr Methanol
fuel
is a very
high
corrosive
type
of fuel
and should
never be lefb
in bhe carburetor
nhen the day
night
or
of
racing
is over.
puulp and
and
gas.
your
Be sure
flush
the
fuel
carburebor
out
vith
If
kart has an alloy
tank
on it
be
sure
and
it
flush
out
also.
As far
as
gto' a plastic
tanks
fuel
tank
fuel
is my choice
for
nethanol
fue1.
Is this
the vhole
story
and all
the trix?
No, it's
about
2% out
of
just
you all
one hundred.
I
don I t
know
hori to give
the possible
courbinations r mistakes
and results
that
This
I have nade.
would
take
a lifej ust
But
given
you
naybe
have
tiure.
I
turned
on
lights
a fev
and
a
platform
rorking
to start
rith.
have
If
f
done
that
then
this
has been
well
tso ueeks of time
spent.
s
!;
-:
s6
81
*:
TROUBLESHOOTING
COVER
Be sureall
SCREW
PumpBody
Screws are
t i g h t t o i n s u r eF > B O D Y
perleci seal
attheparting
surfaces.
COVER
-g
scREW
-
-scREEN
-PUMP
R e m o v eC o v e r S c r e w , C o v e r , G a s k e t a n d
screen.Thoroughly clean Screen with clean
g a s o l i n eo r b y b l o w i n g t h r o u g h w i t h c o m p r e s s e da i r . I n s t a l l S c r e e n n e x t t o P u m p
B o d y c a s t i n g ,t h e n g a s k e t . H o l d C e v e r i n
p l a c ea n d t i g h t e nC o v e rS c r e w .
BODY
P u m p G a s k e ta n d P u m p D i a p h r a g mm u s t
pUMp.
o n c a s t p i n s , a t u n d e r s i d eo l O i a DIAPHRAGM
- ' -\ 'l o c a t e
l O n r a g m C o v e rr i m , t o i n s u r e c o r r e c t i n s t a l -
,MpcAsKEr z rj'""?"x?'
:,i;lil:";i ;HR'T.T1'#,
T;::
ATMOSPHERIC
VENT
-DIAPHRAGM
COVER
___\
I D L ES P E E D
R E G .S C R E W
- - - D I A P H RMAIN
AGM
DIAPHRAGM
GASKET
D i a p h r a g mG a s k e t , M a i n D i a p h r a g m a n d
D i a g h r a g mC o v e r C a s t i n g ,m u s t l o c a t e o n
cast pins, at the body rim, to insure corr e c t i n s t a l l a t i o na n d o D e r a t i o n .M a i n D i a phragm must be clean and tree of breaks
o r p u n c l u r e s l.t s m e t a l d i s cm u s tn o t b e c o m e
bent and should always retain tight fit to
rubberizedbody section.
BODY
Conirol Lever must rotate freely on Fulcrum
coNTROL LEVER/lli":;L3^"#;i,:ever
I N L E TN E E D L E
----____g
C O N T R O L SPRTNG
Pressin place
flushwith >BRASS
bodycastang.
I N L E TS E A T
PLUG
METERING
CHAMBER
INSERT
.-
GASKET
CHOKESHAFT
F R I C T I O NP I N
^/
SPRING\
D r a i nP l u g
Screw musl
s e a lt i g h l l y .
To inspect and clean Inlet Needle and
Seat, first remove Fulcrum Pin and Control
Lever, then inlet needle. The Inlet Seat
can now be carefully removed with a
5/16" hex socketwrench.
C A U T I O N : l f I n l e t S e a t i s n o t h a n d l e dw i t h
c a r et h e s m a l l l n s e r l m a y l a l l o u t u n n o t i c e d .
Remove Gasket and replace with new one
b e f o r e r e i n s t a l l i n gI n l e t N € e d l e a n d S e a t
by reversingaboveprocedure
tightly
WELCH PLUG<Welch Plugmustseal
IDLE DISCHf[!!-,0,"
PLUG
-scREW
WASHER
\
(-t1*E;u"'*'
Discharse
Portsmustbeop6n.
v"r*
PACKING
SPRTNG;F^'
frushwiihfrooror
I M P U L S EC H A N N E L
oTlllofson,@*goAe
82
&ryW@K
PA6E
D E S C RPI T I O I I
and 2
IttTR0DUCTI0ll...r.
r.............1
3
.................
.....
.....
T I L L 0 T S 0 I |l | E r S . . . . .
E . C . ' S T A T E - 0 F - T H E - A R T 'T I L L 0 T S 0 I Ia n d I A L B R OR A C I I l G
4 thru 13
CARBURETORS...........o....
........
thru 16
T I t L O T S O l lS C H E I , I A T a
I Cn d S I I A L LP A R T SL I S T . . . . . r . . . . . . . . . . . . . . . . . 1 4
17
HALBRO
.........,...,....
SCHEIIATIa
Cn d S I I A L LP A R T SL I S T
and 19
B R I G G Sa n d S T R A T T 0 Il lI O T O RS C H E T ' { A T I C . . . . . . . . , . . . . . . , . . . .
....18
and 2L
...20
B R I G G Sa n d S T R A T T OP
..........
I |A R T SL I S T . . . . . . . . ' . .
22
B R I G G Sa n d S T R A T T 0 IT| 0 0 L S . . . . .
.........,.....
.....
2
3
P R o P 0 R T I I { GT 0 0 L S . . . . . . . . . . . . . .
.....
.........
2
4
E
[
{
D
0
R
S
E
I
4
E
I
|
T
.
.
.
.
.
.
o
.
.
sc0TTIE CAGLE
o...
...........................
( P A R Tt l ) . . . . . . . . . . .
B R I G G Sa n d S T R A T T o IBI o X S T o C KB L U E P R I I I T
,.,25 thru 29
B R I G G Sa n d S T R A T T OB
thru 34
f IO XS T 0 C KB L U E P R I T I(TP A R T, 2 r . . . . . . . . . . . . . . 3 0
B R I G C Sa n d S T R A T T OB
thru 37
I I0 I S T O C KC A l l B L U E P R I ] | T I ! | G . . . . . . . . . o . , . . . . . 3 5
B R I G G Sa n d S T R A T T 0 I' IF R 0 l , lB O XS f 0 C K T 0 S U P E RS T 0 C K ' . . . . . . . o . . . . 3 8 t h r u 4 4
E.C. CAll TECHI|OLOGY.....
... o.....45 thru 52
..........
E . C . T E S T B E I | C H' P R O T E C ' . . . . .
and 54
..... ...53
. A L } I O S TE V E R Y T H I I IYGO UI I A ] I T E DT O K ] I O TA B O U TT I L L O T S O I I
CARBURETO
BR
L U E P R I I I T I I I Gz'l C l C L E a n d 1 / C Y C L E . . . . . . . . . . . . . . . . 5 5
thru 61
T I L L O T S 0 I |B L U E P R I I I T I I { [G/ C Y C L E . . . . . . . . . . . . . . .
........62
thru 69
T I L L o T S o i l , E . C . ' S T A T E - 0 F - T H E - A R T 'H L - 3 4 8 CB L U E P R I I t T I i l G
4 / C Y C L E , S U P E RS T 0 C K , L I t T t I T E D
I t 0 D I F I E D , t l l H I D G E T ,J R .
D R A G S T E RI I,O D I F I E Da n d 0 P E t l 4 / C Y C L E S . . . . . . . . . . . . o . . . . . . . . . . . 7 0 t h r u 8 1
T I L L O T S O TTIR O U B L E
82
SHOOTITIG..
t......
E.C. lloTES.....
. r... 83
I]lDEXo....
84
..............,
...............
i
'keersYA"#tfllfl{Ilfr
M y 2 5 p l u sy r s .E x p e r i e n c ies c h e a p e trh a ny o u r M i s t a k e s .
1309 Ofd Charlotte Pk.,Dickson,Tn.37055' Pl{.615' 446-6t07
84
P@&e@&@g
8@BWA
I E R M S:
A l , L o t L d e r L tw i L L b z , s h i p p e d U . P . S . o r L h c t w z v e t L q o u n z q u e t t C . 0 . 0 . ,
u n I - e t , s d u L L y s a q m e n ta e c o m p a n i e t q o u n o , L d u L . S a ua - r j 0 u t t a e L I t h z
( u L I - p a " t l m e n t .) n d e n w i L L b e t h i p p e d
C.0.0. clrtanget bq including
c
o
L
.
L
e
e
t
.
[nzight
PAVMENT:
Centi|izd
c h e c l z , C a , 5 l t i e n ' , se h z e h o , L u . S . r r o 6 t a L m 0 n e q 0 t L d e r l .
P z n , s o n a [ -e L t z c h t w i L L d e l a , q A o u , L l t L d e r Lt i L L i t c L z a n t o u t L b a n b .
D e a . ( - e L6' c l m p a " n u c h e e l z , sw i L L o n L q b e e x e e . p t e d a - d t e n e l - z a n i n g w i t l t
E.C. Didt. din.rt.
F o n z i g n o , L d e , L Lm u t t b z q e c o m p a n i z d b q p n z p a q m z n t i n
dnawabLz on & U.S. $a"ntz.
u. S. Fund,s
RETURNS:
No rtetutttt wiLL be zxceptzd wLthout jtz dtton E.C. 0Ltt.
attz good (:on ctedit 0)L exchangz onLq.
ALt- rtetunnt
E A C KO R O E R S :
Wz rtnivz
t c t m a , i n t a i n a . e u n t e n t i n v e n t o n t l . E a - c h o t L d e t L tu L e h e L d
3 0 d a q . t , d t t h e o n d o d t h a - t t i m e , i t w i L l - b e n e c e t t a . r L r Jt o ) L e o , L d e r l .
CLAlMS;
A L t - c ) L d u L A i l L Q , e a r L e ( 1 u L { - ty1t a e t z z d b t 1 E . C . 0 L , s t . T h e c a , L n i Q . n L t a ' s t l ' t e
) L a - L p 0 n , s L b i l i t t T6 c , n A c ) u t Lg c t o d , sd n o m t h e , t L m e L t L z a v e , s E . C . D i a t .
until
i t i A d e I - i v u l e d t o t i l u . A L L c l a i m , s 6 o n d a . m a g eg 0 t o t h e
cannLen-.
I / A R R A N I VA N D G U A R A N T E E :
A t - L m e n e l , t a " n deL t d i y t ) L i b u t e d b q E . C. L , s g u a n o . n t z e d i n a . c c o n d a n c e
w i - t h t l , t e ,m a n u d a c t u t e t t ' . t o u ) n t e n m a o 6 w a t n a . n t q . \ l e t h a L L n o t b z
0 t L c o n Ae - c l u e n t i o . L d a m a . zgt .
L i a b L z d on i n d i n e c t
PRlCES:
Pnieet
pniezt
and tpzeidicatLctn's tub jeet
a n e F . 0 . B. E . C . B i n t 0 i , s t .
to
cha.ngewithout
notLcz.
AI-I-
H d UR S:
Mondatl - Fnidaq, 9:00 A.M. ta
S u n d a q, g o f r e n a " e i n g.
Thanlz qou 6on rjoun PLt Stop with
E.C. 3i,Lt Di,stnLbutlnq
? - - Satunda"q, tometimzb,
u8.
tttA mq.