Kart Owner`s Manual
Contents
1. The open disc brake system is not designed to work with kart upside down if the kart is turned upside down or on its side the air bubbles in side the reservoir tank may move in the direction of the callipers In this condition the brake may not work correctly and a serious accident could occur Before driving the kart be sure to operate the brake pedal or lever a few times to check that the brakes operate normally If the brakes do not operate normally stop using the kart and consult a dealer Front and Rear Combination Foot brake Master Cylinder Rear Foot brake Master Cylinder Open system Open system Jo ee Front Hand brake Master Cylinder Rear Foot brake Master Cylinder Open system Closed system 16 ECN DEI Karr racine Brake Master Cylinder After fitting a seat in your kart 1 Adjust the footrest to your correct position Adjust the pedal initial position with pedal stopper M6 bolt then tighten the M6 nut Install the brake cable or brake actuating linkage KZ between the pedal and master cylin ders 4 On the pedal there are four positions available for the cable or linkage photo 1 wN The higher position less pedal stroke less braking power The lower position more pedal stroke more braking power CAUTION Brake master cylinder lever should be full returned position when the brake pedal is not actuated photo 2 5 Install emergency cable with cable clamp2. Like any sport karting involves risk of injury and damage By choosing to drive a kart you assume the responsibility for that risk so you need to know the rules of Safe and responsible driving and of proper use and maintenance Proper use and maintenance of your kart reduces risk of injury Mechanical Safety Check Routinely check the condition of your kart before every drive Nuts bolts screws amp other fasteners Because manufacturers use a wide variety of fastener sizes and shake made in a variety of materials often differing by model and component the correct tightening force or torque cannot be generalized To make sure that the many fasteners on your kart re correctly tightened WARNING Correct tightening force on fasteners nuts bolts screws on your kart is important Too little force and the fastener may not hold securely Too much force and the fastener can strip threads stretch deform or break Either way incorrect tightening force can result in component failure which can cause you to loose control and crash Brake Safety Check Before each drive always check the brake for proper function and the brake pads for wear and that there is no system damage resulting in fluid leaks ZAX WARNING If fluid leaks occur immediately stop using the kart and consult a dealer ZAX WARNING The callipers and disc rotors will become hot when the brakes are operated so do not touch them immediately after driving other wis
3. ECN IED Karr racine Kart Owner s Manual www tecnokart com 2 27 MED Karr racine Introduction Thank you for choosing Tecno kart You have in your possession one of the finest kart products in the world We are proud to be your brand of choice The following pages will provide you with the information you need to properly use adjust maintain and service your new kart Enjoy Karting This manual contains important safety maintenance and service information Read it and keep it for reference This document is subject to change without notice EZEN TED ROSI Contents 1 General warning 2 Seat installation 3 Track adjustment Front Track Rear Track 4 Height adjustment Front Height Rear Height 5 Toe adjustment Toe IN OUT Direction Slider 6 Ackerman adjustment 7 Caster adjustment 8 Camber adjustment 9 Brake adjustment Open system Closed system 10 Bleeding the brake system Open system Closed system Troubleshooting Tools needed Tool Size T handle hex wrench 3 4 5 6 8mm Socket wrench 8 13 22mm Combination wrench 10 13 17 25 mm Caster angle gauge supplied Alignment discs Seat fitting plate Threadlock blue Plastic mallet Degreaser Lubrication Recommended torque values M5 bolts 3 to 5 Nm M6 bolts 6 to 12 Nm M8 bolts 12 to 24 Nm M10 bolts 24 to 44 Nm T handle hex wrench and Allen key wrench Combination wrench ERCA MED RIT 1 General Warning
4. Recommended initial rear track width Dry condition 1400mm distance of the outside of the two wheels 230mm with 88mm length rear hubs and 212mm wheels 63mm backspace Wet condition 1380mm distance of the outside of the two wheels 230mm with 88mm length front hubs and 184mm wheels 63mm backspace MT WED marr racine 4 Height Adjustment Front can rise and lower the front ride height chang ing positions of the two 4 5mm spacers between stub axle and caster regulator la Loosen the king pin using a 13mm socket wrench and 17mm wrench and remove M10 nut 2 Remove the king pin from the stub axle di Slide the stub axle out of the frame Be careful not to lose the spacers and washer as they may fall while removing the stub axle Set the spacers where you want then install the king pin Tighten the king pin and check camber and toe ada 4 i gt Di bs K gt i A 7 7 L i 5 4 3 Low front ride height Middle front ride height High front ride height high mount stub axle middle mount stub axle low mount stub axle Recommended initial front height Dry condition Medium ride height Fis3 Wet condition Medium ride height Rear ride height can be changed in 3 positions Loosen all M8 hexagonal bearing carrier fixing bolts Remove two bottom end fixing bolts from each bearing carriers Slide the rear axle up or down ward Install two fixing bolts to each bearing
5. Keep in mind the kart frame is flexible When the driver sit on the kart the camber angle move slightly to negative Negative camber Photo 1 om Positive camber Nar i Positive camber Negative camber Camber Set up L Set the alignment discs on the wheel hubs Maximum positive camber 2 Measure distance of two discs at top and bottom 3 Loosen the king pin with a 13mm socket wrench and a 17mm Maxum combination wrench 4 Turn the eccentric cam with a 25mm wrench photo 1 PEGAN CAMEE 5 From neutral position photo 2 Turn symbol I to inward maximum 90 photo 3 positive camber Turn symbol I to outward maximum 90 photo 4 negative camber 6 Tighten the kin pin to 35Nem 7 Repeat step 2 Recommended initial camber angle Dry condition Negative 2 mm C D Alignment disc diameter 260mm Wet condition Negative 2 mm 15 j g aj KART RACING 9 Brake Adjustment System Configuration Open and Closed system Open system is designed so that as the brake pads become worn the pistons gradually move out ward to automatically adjust the clearance between the rotor and the brake pads Closed system is that the pistons return the same position every time when the brake pads become worn should be install the shims between pads and pistons manually Open system you can see the reservoir tank on the master cylinder which closed system has not
6. The tension of the emergency cable should be slightly looser than the main brake cable or actuating linkage 6 For adjusting the front and rear brake balance turn the knob on the brake actuating linkage clockwise to increase rear brake stopping power counter clockwise to increase front brake stopping power only for tandem master cylinder photo 3 Brake actuating link X Emergency brake cable and clamp te Pedal stopper bolt Brake actuating link Emergency brake cable and clamp Brake balancing Reach adjust Screw Hand Brake OB Hand pump lever reach adjustment This refers to the position of the lever relative to the steering wheel Using 3 mm hex wrench turn the screw clockwise to increase distance counter clockwise to decrease distance Put one drop of medium strength threadlock on the screw 17 NERO Kans RACING erone Catiper Disc Rotor Remove the safety bolt from the caliper photo 2 Remove the pad guide screws photo 3 not for the calliper with magnet insert pistons 3 Slide out the old pads and shims from the caliper photo 4 4 Push the piston back in the caliper body completely while being careful not to twist it ACAUTION If the piston do not go back completely in the caliper may be too much brake fluid in the system In this case remove the reservoir tank cap and diaphragm then push the piston back in the caliper Note that some fluid may over flow from the reser
7. carriers Tighten all fixing bolts Check the friction of the axle rotation N e PEPEN Recommended initial rear height Dry condition Medium ride height Wet condition Medium ride height to high ride height so much water Bearing carrier fixing bolts 10 mJ gia KART RACING 5 Toe adjustment Toe angle refers to the longitudinal angle of the wheels on the kart Toe n Out Zero toe angle means the front wheels parallel to both each other and to the kart Toe in means the front of the wheels are angled inwards towards themselves Toe out means the front of the wheels are angled outwards away from each other Fig Major toe settings effects are tire wear straight line speed and corner entry handling Zero toe gives minimum tire wear and maximum straight line speed Toe out reduces straight line speed but help provide extra grip in corners Generally in dry condition O to 1mm toe out is recom mended Keep in mind When the kart is loaded with driver fuel and itself the toe angle move slightly to tn If you change caster or camber setting you will have to reset toe setting as well Toe out Zero Toe In A 2 Direction Slider Default tie rods fixing positions l Before fixing the rod ends to the stub axles and the steering column make sure that the thread of the rod ends are completely screwed by hand to each side of the tie rods One side of the tie rods have reverse thread so turn
8. change rapidly in the race Toe out for Wet condition L Loosen two M8 hexagonal fixing bolts Zi Slide Direction Slider to forward 3 Tighten the fixing bolts Direction Slider Recommended toe out Wet condition 10mm 6 Ackerman Adjustment Ackerman is the term used to describe steering geometry that causes the inside front wheel to turn tighter than the outside front wheel If you attach the tie rods to inside hole of the stub axle you in crease the Ackerman effect means that the difference in the an gles of the inside and outside wheels is increased If you attach the tie rods to center hole of the steering column decrease the Ackerman effect With 4 hole of each side of the steering column you can change the response of the steering wheel Using lower holes the steer ing wheel more sensitive and need less rotating the steering wheel ACAUTION Length of tie rods does not fit all ackerman positions The rod ends must be screwed 15mm minimum to the tie rods If it is less than 15mm Please change the tie rod to longer one O Upper hole Inside hole Outside hole 12 FET WED Karr racine 7 Caster Adjustment The caster is the angle between the king pin axis and the vertical axis of the kart when viewed from the side of the kart The caster produces forces that tend to return the steering to center during cornering In addition to the caster angle is very important for t
9. it counter clockwise to tighten The length of the two tie rods are same or slightly different depend on the frame If different install shorter one to left side Because The steering column has a small offset to left side 2 Bolt on the rod end to the outside hole of the stub axle and the 3rd hole of the steering column This Is basic position 3 Slide Direction Slider to full backward then tighten two M8 bolt with 13mm wrench 4 Install alignment discs Fig3 on the front hubs and positioning the steering wheel to neutral po sition Now you find the maximum toe out angle on your kart 5 Measure the distance of the front end A and rear end B of the discs and turn the each tie rods to adjust toe angle Fig4 Recommended toe out Dry condition A B 0 to lmm 6 Measure the distance between stub axle spindle and rear axle on each side If it is same tighten 4 lock nuts of the tie rods If it is different re register each tie rods open one close other then tighten lock nuts 260mm Tie rods fixation on steering column alignment discs Sold separately SET MED Karr racine Direction slider is our original quick toe adjusting system Direction Slider Once you set up toe angle you can increase the toe out without loosen the lock nuts of the tie rods Only loosen two bolts on the direction slider and slide it for ward Measure toe out then tighten bolts This system is useful when weather condition
10. pistons don t protrude more than 4mm from the caliper In this situation you need to add the shims or replace the brake pads When adding shims only one side of the caliper they need centering of disc rotor We recommend that the rear brake pads will need replacing when the friction material is Fig l Guide screw holes worn down to a thickness of 5mm Pad shim I nstallation I nstall pad shims L Remove upper guide screw 2 Push lower guide screw then install shims between brake pad and piston Figi 3 Install upper guide screw 4 After tighten upper guide screw the shims Should be free from brake pad Available shim thickness 0 8 mm Half Caliper 19 SET WED Karr racine Centering of Disc rotor 1 ve Make sure that all set screws of the axle bearings are tightened Loosen the disc carrier clamp bolts Moving the disc carrier center the disc rotor Do not hammer the disc rotor Tighten the clamp bolts Check the drag of the disc rotor ACAUTION Disc brakes have a burn in period and the braking force will gradually in crease as the burn in period progresses Make sure that you are aware of any such increases in braking force when using the brakes during the burn in period The same thing will happen when the brake pads or disc rotor are replaced CAUTION Use soapy water or a dry cloth when carrying out cleaning and mainte nance of the master cylinders and calipers Do not u
11. the adapter Current caster angle appear on the display Fig4 8 Loosen one of two M6 set screws If you want to increase the caster angle loosen the front side set screw If you want to decrease the caster angle loosen the rear side set screw 9 Turn clockwise another set screw Then the caster regulator begins to move 10 The display will read caster angle 11 Turn clockwise the set screw which is loosen before until the screw has contacted the caster regulator surface 12 Tighten the M14 nut to 55Nem 13 Tighten the two set screws to 2 5Nem 14 Install the rubber cap 15 Check the toe angle A e AM Example The LCD display show 16 4 degrees Recommended initial caster angle Dry condition 18 degrees Wet condition 23 degrees After the calibration The display must remain on the same side right or left at every measurement This is relative caster angle to calibrate on the frame Real caster angle the reference surface is the ground is variable de pending on the front amp rear axle height and also depending on the tires that you are using 14 g es KART RACING 8 Camber Adjustment The camber is the angle between the vertical axis of the wheel and the vertical axis of the kart when viewed from the front or rear The positive camber mean the top of the wheel is farther out than the bottom The negative camber mean the bottom of the wheel is farther out than the top
12. away from direct sunlight or heat Tools needed 5mm hex wrench closed system 8mm closed end wrench Syringe Anti squirt bridge open system Syringe adapter for master cylinder closed system Plier Drain tube Fluid container Anti squirt bridge Brake fluid Fluid container Safety glasses amp nitrile groves Isopropyl alcohol Rags W Closed system Nitrile groves ve ks Syringe adapter i e a gt syringe lt acme a gt Plier Bleed kit Bleed kit 5 for open system for closed system 5mm hex wrench Parts No 480 003 Parts No 480 004 8mm wrench ACAUTION Use safety glasses when handling and avoid contact with eyes Contact with eyes may result in irritation In the event of eye contact flush with fresh water and seek medical assistance immediately Use gloves when handling Contact with skin may cause a rash and discomfort In the event of skin contact wash well with soap and water Keep out of reach of children 21 SET WED Karr racine Open system Master cylinder with reservoir tank l Remove the reservoir tank cap and diaphragm photo 1 2 Insert the anti squirt bridge in the reservoir tank photo 2 3 for front brake go to front brake step 1 p 23 3 Attach a 8mm closed end wrench to the bleed nipple on the caliper 4 Fill the syringe with 40 ml brake fluid and connect a hose to the bleed nipple photo 4 di L
13. e spindle you should tighten the nut just enough so that there is no lateral play of the wheel hub Minimum widt Medium width 6 Check the friction of the hub rotation They do not have excess drag Recommended initial front track width Dry condition 20mm space inside of the hubs with 90mm length front hubs and 130mm wheels 53mm backspace Wet condition 35mm space inside of the hubs with 90mm length front hubs and 130mm wheels 53mm backspace With Front Brake Loosen two clamp bolts on the wheel hubs 2 Slide the wheel hub inward to narrow track outward to wide track 3 Tighten two clamp bolts _ If the front hubs slip in during cornering add ke anti slip spacer between end of the disc car rier and bottom of the wheel hub Figs Dry condition Wet condition Recommended initial front track width is Dry condition On the 2nd line of the disc carrier with 72mm length front hubs and 130mm wheels 53mm backspace Wet condition On the 4th line of the disc carrier with 72mm length front hubs and 130mm wheels 53mm backspace 8 ECN MED arr racine Rear Track Set up I Loosen two clamp bolts on the wheel hubs 2 Slide the wheel hub inward to narrow track outward to lai 9 wide track 3 Tighten two clamp bolts If the rear hubs slip in during cornering add anti slip spacer between end of the axle and bottom of the wheel hub 50mm axle only Fig2 Maximum 1400mm CIK rule
14. e you may get burned Check that the brake components have cooled down sufficiently before attempting to adjust the brakes Be careful not to allow any oil or grease to get onto the disc brake ACAUTION rotor and brake pads otherwise the brakes may not work cor rectly ERCA MED ENIT ACAUTION Vapor lock may occur if the brakes are applied continuously This can then result in a sudden increase in the brake pedal stroke and spongy pedal feeling Vapor lock is phenomenon in which the oil inside the brake system becomes heated which causes any water or air bubbles inside the brake system to expand A WARNING If the disc brake rotor is cracked or deformed immediately stop using the kart and consult a dealer Changing Components or Adding Accessories There are many components and accessories available to enhance the comfort performance and appearance of your kart However if you change components or add accessories you do so at your own risk The kart s manufacturer may not have tested that component or accessory for compatibility reliability or safety on your kart Before installing any component or accessory make sure that it is com patible with your kart by checking with your dealer Be sure to read understand and follow the instructions that accompany the products you purchase for your Kart AWARNING Failure to confirm compatibility properly install operate and main tain any component or accessory can result in ser
15. end wrench from the bleed nipple Squeeze the brake pedal as far as it will go The feel of the pedal must be stiff at this point If the brake pads are new go to step 17 If the brake pads are used go to step 16 push the caliper pistons back in the caliper body Remove the anti squirt bridge from the reservoir tank Fill the reservoir tank with brake fluid Fit the diaphragm and gently tighten the reservoir tank cap Be careful not to get any fluid on parts such as the rotor and brake pads Move the brake pedal several times to adjust the pad position Front brake 1 2 3 4 ii Fill the syringe with 40ml brake fluid and connect a hose to the bleed nipple on the caliper Connect the drain tube to the bleed nipple on another caliper and place the free end into an empty container Open both bleed nipples with 8mm open end wrench Lock the master cylinder lever about 1 4 stroke from the initial position to close the port from cylinder to reservoir tank photo 14 15 Push the plunger of the syringe to add fluid When the fluid come out to the drain tube close the bleed nipple connected to the drain tube Release the master cylinder lever continue to open system step 6 p 22 Need to bleed both calipers Ke 23 SET MED Karr racine Closed system Master cylinder without reservoir tank 1 Remove the M5 bleed port screw and attach the bleed nipple on the master cylinder photo 1 2 2 Connect the syrin
16. ge A without plunger to the bleed nipple photo 3 3 Attach a 8mm closed end wrench to the bleed nipple on the caliper 4 Fill the syringe B with 40ml brake fluid and connect a hose to the bleed nipple on the caliper photo 4 Y BM syringe B SA Photo 3 di Loosen the bleed nipple by 1 2 of a turn to open it 6 Push the plunger of the syringe B to add fluid The fluid will start coming out from the bleed nipple of the master cylinder Fill all the fluid in the system photo 5 7 Pull the plunger of the syringe B Brake fluid and air return to the syringe B Maintain the fluid level of the syringe A so that air is not drawn in through the port It may help to shake the hose gently or to tap the caliper gently with a screwdriver photo 6 7 8 Repeat step 6 7 until there is no more air mixed in with the fluid that is coming out 9 Tighten the bleed nipple of the caliper and remove the syringe B and the 8mm closed end wrench from the bleed nipple 10 Slowly operate the brake pedal about 2 to 3 times If still Air remains in the master cylinder the bubbles will rise up through the port into the syringe A photo 8 11 Once the bubbles stop appearing remove the syringe A using a plier photo 9 10 12 Remove the breed nipple Fluid level in the breed port should be maximum 13 Tighten the M5 bleed port screw Be careful not to get any fluid on parts such as the rotor and brake pads photo 11 z 14 O
17. he kart which has not the differential system It Help lift up the rear inner tire for better cornering Increasing caster angle the driver need more force to steer Our P T system provide adjustment angle 10 to 28 without changing camber angle that many other karts are not Digital caster angle gauge is useful for precision adjustment Caster angle e A ll d f a gt x 7 l gt i Mi jj fan t MI i w i a Knock pin Caster adjustment Regulator shell For gauge adapter M6 set screw Part of frame Lock nut I P T system Cut away model King pin Eccentric cam Rubber cap C clip Caster regulator For break off engagement 13 ECN MED Karr racine Caster Set ub Before starting set up the kart must be set on the stable kart carrier or stable kart stand When the kart is moved during this operation repeat step 5 for re calibration 1 Remove the rubber cap Fit 2 Loosen the M14 nut using a 22mm socket wrench di Continue turns the nut counter clockwise until the caster regulator breaks off an engagement 4 Turn the nut clockwise to cancel lateral play 5 Set the Digital caster angle gauge on the frame Turn on and press the ZERO to set the gauge to 0 0 degrees which calibrates the reference surface Fig 2_ 6 Set the adapter to the upper and lower knock pin The adapter must be parallel to the frame Fig3 7 Set the Digital caster angle gauge on
18. ighten the rear fixing bolt photo 7 4 Operate the brake pedal or lever so that the rotor is being clamped by the pads then loosen the two caliper fixing bolts and re tighten definitively 5 Leave the brake pedal or lever check drag of the disc rotor 18 Karr racine Rear Caliper Disc Rotor Changing Brake Pads Remove the pad guide screws Extract the pad shims forward Slide upward the old pads from the caliper Push the pistons back in the caliper body completely while being careful not to twist it CAUTION If the piston do not go back completely in the cali per may be too much brake fluid in the system In this case remove the reservoir tank cap and dia phragm then push the piston back in the caliper Note that some fluid may overflow from the reser voir tank at this operation 5 Clean the inside of the caliper with a clean rag and insert the new pads photo 1 Install the pad guide screws Check centering of the disc rotor Move the brake pedal several times to adjust the pad position AUNE RA Brake Pads clearance adjustment Closed system Recommended clearance between disc rotor and brake pads is 1mm to 2mm each side More than 2mm of clearance need to add shims between pad and piston or replace the brake pads photo 3 Open system This is designed that the caliper automatically adjust the clearance between rotor and brake pads But the initial positions of the caliper
19. ions 9 drilling marking point to 8mm and fix with M8 counter P sunk head bolts y 4 A A yO A Weight distribution on rear axle approximate Kart with gear box 56 58kg each side Kart without gear box 52 54kg each side Measure complete kart with driver wear full race gear fuel and water on the flat surface using two or more digital scales Keep weight distribution as even as possible moving seat spaces or mounting position of the ballasts Slightly loosen fixing bolts of the lower seat stays and removable seat stays when kart has too much rear grip Seat moved Forward More grip on the front wheels Seat moved Backward More grip on the rear wheels High seat position More grip Low seat position Less grip Lower seat stay SET MED Karr racine Left side removable Right side seat stays removable seat stay aluminium and plastic lower seat spacer Larger diameter seat washer for seat protection 7 Seat Fitting Plate j g KART RACING 3 Track Adjustment Front Track Set up Without Front Brake 1 Remove the M14 spindle nut with 22mm socket wrench 2 Slide two 10mm spacers onto the axle spindle basic set ting 3 Install the wheel hub 4 Slide one 10mm spacer two 5mm spacers and washer only 25mm spindle onto the axle spindle Fig 2 5 Install the M14 spindle nut and tighten with 22mm socket wrench Maximum width For the 17mm axl
20. ious injury or death ZA WARNING Changing the components on your kart with other than genuine re placement parts may compromise the safety of your kart and may void the warranty Check with your dealer before changing the components on your kart EST MED Karr racine 2 Seat Installation Fitting a seat into the kart is one of the most important operation that will affect the performance of the kart The driver s weight is about half of the total weight of the kart it means the seat placement is most important weight adjustment on the kart 1 Attach the seat fitting plate See next page or simi lar tool under the main frame The plate surface should be 4mm lower than bottom of the main frame tube It means that the bottom of the seat protrude 4mm under the bottom of the main frame tube and should be parallel to the fitting plate Frame Seat f 2 Put the seat on the plate 3 approximate Z size for kart with gear box 180mm Plate Kart without gear box 200mm Figi 4 Mark the positions of 4 holes of the seat stays with mark ing pen Fig l 5 Drilling 4 marking points to 98mm 6 Adjusting distance between the seat and seat stay tabs with the spacers fix the seat with M8 countersunk head bolts photo 3 4 7 Fix one or two removable seat stays to the fixing point of the each side of the main frame photo 4 5 oa 8 Positioning other side of the stay to the seat and marking hole posit
21. oosen the bleed nipple by 1 2 of a turn to open it 6 Push the plunger of the syringe to add fluid The fluid will start coming out in the reservoir tank Continue adding fluid up to the maximum level of the reservoir tank photo 5 6 J Pull the plunger of the syringe Brake fluid and air return to the syringe photo 7 8 8 Repeat step 6 and 7 about 2 to 3 times When push the plunger hold the syringe upright The air in the syringe should not go back into the caliper It may help to shake the hose gen tly or to tap the caliper gently with a screwdriver photo 9 9 Tighten the bleed nipple and remove the syringe from the bleed nipple j pl 22 10 11 12 ECN MED arr racine Squeeze the brake pedal as far as it will go If the feel of the pedal is stiff at this point go to step 15 If it is still spongy go to step 11 Connect the drain tube to the bleed nipple and place the free end into an empty container photo 10 With the brake pedal operated open and close the bleed nipple in rapid succession to release any air bubbles which may be in the calipers Repeat this procedure about 2 to 3 times Then tighten the bleed nipple again photo 11 12 A cAUTION The fluid level in the reservoir tank will drop at this time so be sure to keep adding fluid to maintain the fluid level so that air is not drawn in through the port photo 13 Remove the drain tube and the 8mm closed
22. perate the lever of the master cylinder The lever must be stiff and not have the play If no repeat step 1 to 12 Troubleshooting No braking power Symptoms force Symptoms No braking effort and the pedal reaches the end of stroke Spongy pedal lever Symptoms Reduced braking power and spongy feel when braking Unstable pedal lever stroke Symptoms The feeling of the pedal is not equal in every braking System leak Symptoms after a crash which has wrenched the hose and damaged other items on the brake Or the brake is very old and the seals have worn out ECA WED Karr racine Brake fluid can be seen on the outside of the system usually associated with a loss Please consult your dealer of braking performance A typical cause Is Solution The pedal or lever operates as normal but The brake pads are new and not fully burn in the brake does not deliver a good braking Disc brake have a burn in period and the braking force will gradually increase as the burn in period progresses Pedal lever reaches the end of stroke Solution For open system Pumping the pedal several times to reset the pad posi tion For closed system The brake pads are worn down Add the shims or replace the brake pads If non of the above work then there may be insufficient fluid in the system in which case re bleed or the sys tem has a leak Solution Air in the system Re bleed
23. se commercially avail able brake cleansers or silencing agents as they can cause damage to parts such as seals 20 mij g aj KART RACING 10 Bleeding the brake system Bleeding the brake is the procedure whereby new brake fluid is introduced into the system either as a replacement or to flush out any trapped air There are several reasons why a bleed operation may be necessary for example changing the brake fluid or to remedy a situation described later in the troubleshooting guide Brake fluid Tecno disc brake system contains DOT 4 hydraulic brake fluid We recommend Ate Super Blue Racing fluid and DOT 5 1 fluid will work as well Use of other types of brake fluid in particular DOT 5 silicone based or mineral oil will seriously damage your brake and cause brake failure We draw your attention to the following Use only new brake fluid from a closed bottle and replace the bottle s cap afterwards to pre vent contamination of the fluid Brake fluid will strip paint so wipe off any spillage immediately and clean the area with iso propyl alcohol Brake pads contaminated with brake fluid will need replacing because the braking perform ance of the pad will be greatly diminished Discard old brake fluid in a responsible manner and do not pollute drains or the environ ment Keep the container sealed to prevent foreign objects and moisture from getting inside and store it in a cool dark area
24. the system Solution Air in the system Re bleed the system The brake master cylinder lever does not return com pletely when release the brake pedal Adjust the pedal stopper or prolong the cable Solution Replace the parts Re bleed the system 25 Tecno Kart Racing Corso Torino 95 Tel 39 0125 637034 10019 Strambino TO Fax 39 0125 637100 ITALY E mail info tecnokart com 07 2014
25. voir tank at this operation Clean the inside of the caliper with a clean rag and insert the new pads Install the pad guide screws and safety bolt Check centering of the disc rotor Move the brake pedal several times to adjust the pad position Sa Brake Pads clearance adjustment Front brake system is designed that the caliper automatically adjust the clearance between rotor and brake pads But if you want to shorter pedal stroke add shims between pad and piston photo 5 Recommended minimum clearance between pad and disc rotor is 0 3mm each side Less than 0 3mm may has excess drag When adding shims only one side of the brake pad they need centering of the disc rotor Safety bolt RI The initial positions of the caliper pistons don t protrude more than 2 mm from the caliper body In this situation you need to add the shims or replace the brake pads Available shim thickness 0 6 mm and 1 0 mm We recommend that the front brake pads will need replac ing when the friction material is worn down to a thickness of 3mm ACAUTION If the rotor is worn cracked or warped it should be replaced Centering of Disc rotor im Loosen the two caliper fixing bolts so that the caliper can move sideways 2 Moving the caliper sideways center the disc rotor between front edge of the each pad Then lightly tighten the front fixing bolt photo 6 di Center the disc rotor between rear edge of the each pad and lightly t
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