USER MANUAL TECH F1 R Rev 3- 22/03/08

USER MANUAL
TECH F1 R
ENGINE KART

All information in this publication is based on the latest product information available at the time of approval for printing.
Technique Engineering s.r.l. reserves the right to make changes at any time without notice and without incurring any
obligation.
No part of this publication may be reproduced without written permission.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

IMPORTANT NOTICE

THIS ENGINE IS DESIGNED AND MANUFACTURED FOR COMPETITION

USE ONLY AND IS SOLD “AS IS” WITH NO WARRANTY.

IT DOES NOT CONFORM TO FEDERAL VEHICLE SAFETY STANDARDS AND

OPERATION ON PUBLIC STREETS, ROADS, OR HIGHWAYS IS ILLEGAL.

THE EXHAUST SYSTEM BECOMES VERY HOT DURING OPERATION, AND

IT REMAINS HOT AFTER OPERATION.
NEVER TOUCH ANY PART OF THE HOT EXHAUST SYSTEM

THIS ENGINE VERSION IS FOR HOBBY DRIVER –

FOR DMSB HOMOLOGATION vs. USE NRK noise reduction kit ( 92 Db A) .

ANY MODIFICATION TO THE ENGINE ORIGINAL VERSION

MANUFACTURED AND DISTRIBUTED BY TECHNIQUE ENGINEERING WILL
PREVENT THE PARTECIPATION TO THE COMPETITIONS REGULATED BY
THE DMSB FEDERATION.

WARNING: IT IS MANDATORY TO WEAR CLOTHING CONFORM TO RACING

USE.
WHILE STATIONING WITH SWITCHED ON ENGINE IT IS FORBIDDEN TO
STAND NEAR AND TO CARRY OUT ANY MAINTENANCE OPERATIONS.
IT IS FORBIDDEN TO USE OR TO WEAR CLOTHING, OR LONG HAIR OR
ANY OTHER GARMENT/THING THAT COULD BE TRAPPED BY MOVING
MECHANICAL ORGANS OF THE VEHICLE

This manual should be considered a permanent part of the engine and should remain with the
engine when resold

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USER MANUAL TECH F1 R Rev 3- 22/03/08

TECHNICAL ENGINE DATA

Operating cycle 4 Stroke

Number of cylinder One

Bore 79 mm

Stroke 50,9 mm

Total Cubic Capacity 249,495 cc.

Stroke / Bore 0,644

Number of valves 4

Angle valve inlet 10° - exhaust 11,5°

Carburetor type DELL’ORTO PHF 30

Maximum RPM 13000 RPM/1’

Valve train timing gears

Starter system electric starter motor 450-500W

Lubrification system forced feed lubrication at dry oil pan

Cooling system Liquid-cooled with external pump + radiator

Transmission system centrifugal clutch

Ignition digital capacitive with variable spark advance

Engine weight 17,0 Kg included engine plate holder

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USER MANUAL TECH F1 R Rev 3- 22/03/08

C=check
R=replace
L=lubricate
CL=clean ENGINE HOURS OPERATION
2 10 15 20 25 30 35 40 45 50 NOTES

ENGINE OIL R R every 4 hours Page no.15-16-17

Filter oil R R every no. 2 oil replace page no. 15-16-17

VALVES C/R See service manual
Valves clearance C C C C Page no. 8-9-10-11-12
Spring Valve C C/R See service manual
Decompressor cam screw C C C Page no. 13
Decompressor cam spring C C C Page no. 13
PISTON R See service manual
Piston rings R See service manual
Piston pin R See service manual
CYLINDER C C See service manual
CRANKSHAFT C See service manual
Connecting rod R See service manual
Connecting rod roller cage R See service manual
Connecting rod pin R See service manual
Crankcase bearing R See service manual
CL - CL - CL -
STARTER MOTOR page no. 19
L L L
Starter axis gear (Bendix) L L L page nro 22
Tighten starter motor
C C C page no. 19
support
C/
Rubber fixing starter motor C/R page no. 19
R
Charge the battery before use the kart
BATTERY C (everytime)
SPURK PLUG C / CL page no. 18
CLUTCH C C page no. 20-21-22
Clutch springs C/R C/R C/R C/R Page no. 22
Clutch pins CL-L every 5 hours Page no. 22
Sprocket roller cage CL-L every 2 hours page no. 20-21

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USER MANUAL TECH F1 R Rev 3- 22/03/08

The respect of these maintenance preventive procedures will ensure a more reliable running, a longer duration
and will limit expensive revision operations of the engine.

ATTENTION: we recommend to follow the under mentioned rules, in order to do the

maintenance operations at the best:

LAYOUT AND CLEANING OF THE REMOVED COMPONENTS

It is easy to confuse the disassembled components.
Arrange the components according to the disassembly order and
always clean them before their mounting.

SOLVENTS
During the cleaning of the components it is advised to use solvents
with a high degree of inflammability. The solvent with a high degree
of inflammability must be used according to the prescriptions of the
solvent’s producer.

VISUAL CHECK
Check the removed components to determine any presence of wear,
corrosion, discoloring or other types of damage.
Refer to this Manual’s appropriate sections for the life service limits of
the single components. Replace the damaged components or the
components which have exceed the life service limits.

ATTENTION:

The reuse of worn or damaged components can cause

serious accidents.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

SPARE PARTS
The spare parts must be the original by TECHNIQUE
ENGINEERING or recommended by TECHNIQUE ENGINEERING.
Gaskets, O-ring, oil seals, snap rings and split pins must be replaced
at the moment of dismantling.

TIGHTENING TORQUE
Fix the elements to the specified tightening torque by means of a good
quality torque wrench.

ATTENTION:
A not correct fixing torque applied to a bolt, die or screw can
cause serious damages.
.

OIL SEALS
Not remove the pressure-housed oil seal(s), if not absolutely
necessary.
Replace them when they are removed.
Install the new oil seal(s) with their manufacturer’s logo and
dimension references (= the stamped letters must be on the side at
sight) facing outward.
During the oil seal(s) installation, apply on the seal lips a light coat of
lithium based grease.

BEARINGS
Install the bearings and the new oil seal(s) with their manufacturer’s
logo and dimension references (= the stamped letters must be on
the side at sight) facing outward.
Oil the bearings very well when installing.

ATTENTION:
Do not use compressed air to dry the bearings: it can damage
their surface.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

STRENGTH
When it is necessary, remove the blocked screws with LOCTITE
using a pulse screwdriver. If it is necessary, tap and use a mallet
covered with plastic.

ATTENTION:
Pay attention that during the disassembly and assembly
operations the application of an exceeding strength can cause
expensive damages or difficult reparation.

LUBRIFICATION
Use oil and grease recommended by TECHNIQUE ENGINEERING.
Other brands can be similar in the scope and appearance but be of
inferior quality.
During the reassembly, lubricate the components which have
relative movements: roller cages, bearings, oil seals, o-ring.

ELECTRIC CONNECTIONS
Verify the absence of spots, rust, humidity, etc.. on cables,
couplers and connectors.
1. Disconnect:
• cable
• coupler
• connector
2. Check:
• cable
• coupler
• connector
Humidity → Dry with a ventilator.
Rust /spots → Connect and disconnect many times.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

This operation can also be done with the engine mounted on the go-kart.
During this operation the engine temperature must be at ambient temperature and the piston at the top
dead center (TDC).

ATTENTION: THE NO RESPECT OF THE VALVE CLEARANCE DAMAGES SERIOUSLY THE ENGINE.

As first operation, remove the spark plug cup and the spark plug. Before removing the spark plug, clean with
compressed air the possible dirt accumulated in the center, in order to avoid the fall into the cylinders.

Cut the manufacturer’s cover cylinder head seal.

Attention: after having removed the manufacturer’s seal,

replaced it by an authorized distributor.
This seal is necessary to participate to the ADAC VT 250
championship and guarantees the engine homologation
conformity.

Unscrew the 6 (six) M5 screws of the cover cylinder head.

Tightening torque: 5 N·m (0.5 Kg·m) [3.6 lbf·ft]

Remove the cover cylinder head paying attention not to

damage the gasket.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

Turn the crankshaft with a n° 19 wrench to find the piston

TDC.

Measure the EXHAUST valve clearance using a feeler gauge

between the tappet and the cam lobe.

During this operation pay attention than the

decompressor pin is not pushing the tappet downwards.

The 0,15 mm feeler gauge must freely pass, while the next
0,20 mm blade must absolutely not pass through.

In case the valve clearance is not rightly regulated, replace

the shim (A) with one of another measure.

EXHAUST VALVE CLEARANCE

Maximum valve clearance allowed 0,15 mm, not go

beyond.

ATTENTION: NOT GO BEYOND THIS LIMIT,

OTHERWISE YOU WILL DAMAGE SERIOUSLY THE
ENGINE.

EXHAUST valve clearance tolerance: 0,15 – 0,18 mm.

(A)

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USER MANUAL TECH F1 R Rev 3- 22/03/08

Measure the INLET valve clearance using a feeler gauge

between the tappet and the cam lobe.
.

The 0,10 mm feeler gauge must freely pass through, while

the next 0,15 mm blade must absolutely not pass through.

In case the valve clearance is not rightly regulated, replace

the shim (A) with one of another measure.

INLET VALVE CLEARANCE

Maximum valve clearance allowed 0,10 mm, not go

beyond.

ATTENTION: NOT GO BEYOND THIS LIMIT,

OTHERWISE YOU WILL DAMAGE SERIOUSLY THE
ENGINE.

INLET valve clearance tolerance: 0,10 – 0,13 mm.

(A)

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USER MANUAL TECH F1 R Rev 3- 22/03/08

VALVE CLEARANCE ADJUSTMENT

Be sure that the piston is at the TDC (on compression

stroke).

At the TDC the cam references are aligned with the cylinder
head surface.

Make the operation on just one camshaft at the time, in

order not to confuse the fixing camshaft and the tappets.
Be careful to reinstall shim and tappet in their original
place.

Unscrew the 6 nuts of the fixing camshaft paying attention

not to let fall the nuts and washers in the cylinder head.

ATTENTION:
the nuts and the washers are of a special type, not
replace them with any other type.

Remove the fixing camshaft, paying attention not to let fall

the dowels in the cylinder head.

If it is necessary, help yourself by tapping the outside of the

fixing camshaft with a plastic screwdriver handle.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

Lift the central fixing camshaft paying attention to the dowels.

Repeat the same operation with the other single fixing

camshaft of the same camshaft.

Extract the tappets using a magnet.

ATTENTION: when tappets are extracted by the

magnet, also the shim that is present inside the tappet will be
withdrawn.
.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

Measure the extracted shim thickness with a micrometer and

record it.
Choose a new shim with a major or minor thickness
respectively to decrease or increase the valve clearance.

Calculate the new shim thickness using the equation below:

A = (B-C)+D

A = new shim thickness

B = recorded valve clearance
C = specified valve clearance
D = old shim thickness

Install the new selected shim into the seat valve spring
retainer.

Pressing with the finger and doing a little rotation with the
hand, be sure that it is well inserted.

Put the tappet in its seat.

Do this operation also for the adjacent valve, in case you

have previously measured a different valve clearance.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

Remount the camshaft with its reference notches aligned to

the cylinder head surface with the piston in TDC position.

Do this operation also for the other camshaft, in case it has

been disassembled.

ATTENTION:

Tighten the fixing camshaft nuts with a driving torque of:

15 N·m (1,5 Kg·m) [10,8 lbf·ft]

Do not use molybdenum grease or molybdenum oil on

the camshaft nuts, as it may compromise the correct
tighten torque.

Check the decompressor cam assembly to avoid wear or

damage.

Check the decompressor balance weight spring to avoid

damage or tension loss.

Check the decompressor washer: it must not be free, if is not

like, tighten the washer with LOCTITE type 270.

Screw decompressor washer Tightening torque:

5 N·m (0,5 kg·m) [3,6 lbf·ft]

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USER MANUAL TECH F1 R Rev 3- 22/03/08

OIL AND FILTER CHANGE

This operation must be done with the engine demounted from the go-kart.

Start the engine for three minutes, afterwards shut it off.

Wait three minutes after the shutting off of the engine to allow the oil to distribute itself properly inside
the engine

Disconnect the two oil pipes that arrive in the engine from the oil tank.

Once the oil pipes are disconnected, they must be positioned upwards behind the seatback to avoid the
come out of the oil.

Disconnect the breather pipe from the engine.

Disconnect the electric connectors and disconnect the electric starter motor wire bonding.

Extract the carburetor from the rubber manifold and unscrew the fixing plate which fixes the engine to
the kart chassis.

At this point remove the engine from the chassis, in order to be able to do the following operations:

Clean the interested area with solvent very well and

subsequently take away the snap ring.

By means of pliers extract the oil filter cap.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

Remove the used cartridge filter oil and replace it with a new
one.

ATTENTION: use the original oil filter spare parts, as

they derive from a Technique Engineering exclusive drawing.
Do not clean the used filter oil to reuse it, as this can
cause serious engine damages.

Replace the 2 O-ring (A) and then insert the new oil filter in
the cap.

During this operation lubricate all the rubber parts (included

the O-ring ) with oil or grease.

(A)

Reinstall the filter oil cap in its position in the carter, pushing
with moderate strength paying attention not to damage the
O-ring and finally replace the snap ring.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

Afterwards empty the exhausted oil from the oil tank and put new the oil for a quantity of 1,00 liter.

Check the oil level after run the engine for 1 minute at the minimum RPM

MIN.

USE ONLY FULLY SYNTHETIC OIL TYPE SAE 5W- 40 or SAE 10W- 40.

ATTENTION:

BEFORE STARTING AGAIN THE ENGINE, RUN THE ENGINE FOR AT LEAST 20 SECONDS ONLY WITH
THE STARTER MOTOR FORCE, WITH THE OIL PIPES CONNECTED TO THE OIL TANK, WITHOUT
SPARK PLUG AND WITHOUT CARBURATOR.

WHEN THE ENGINE IS STOPPED FOR SOME HOURS, IS POSSIBLE THAT THE OIL INTO THE TANKOIL,
GOBACK INSIDE THE ENGINE, AND YOU DON’T SEE OIL LEVEL ANY MORE.
THEN RUN THE ENGINE FOR 10-15 SEC. AND THE TANKOIL LEVEL WILL BE RESTORED.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

SPARKPLUG CHECK

Do the following operations:

1. Disconnect:
• sparkplug cap
2. Remove:
• sparkplug

ATTENTION:
Before removing the spark plug, remove with compressed air the possible dirt accumulated in the centre
to avoid that it falls in the cylinder.

3. Check:
• Sparkplug type
Not correct → substitute (sparkplug type RG4HC).

4. Check:
• Electrode (1)
Damages / wear → substitute the sparkplug.
• Insulator color (2)
Normal condition is a medium to light tan color.
Anomalous colour → check the engine condition.

When the engine runs for many hours at low speed, the spark plug
insulator will became sooty, even if the engine and carburetor are in
good operating condition

5. Clean the plug with a detergent or a metal brush

6. Measure:
• Plug gap (a)
Use a wire gauge or thickness gauge
Out of specification → RipRegap.

SPARKPLUG GAP (a) : 0,7-0,8 mm

Tightening torque: 18 N·m (1,8 Kg·m) [13 lbf·ft]

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USER MANUAL TECH F1 R Rev 3- 22/03/08

CHECK STARTER MOTOR

Every 20 hours of engine operation, check the rubbers

integrity. Let damage rubbers could damage internal
electrical cable of starter motor

Clean the engine with petrol or solvents, paying attention not

to wash the rubbers.

ATTENTION:

Petrol and solvents damage the rubbers.

Every 15 hours of engine operation, check the screws

tightness.

Tightening torque: 10 Nm (1 Kgm).

Every 10-15 hours of engine operation, lubricate the starter motor pinion with molybdenum grease.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

CLUTCH AND SPROCKET ROLLER GAGE

Unscrew the nut with a pneumatic air gun impact wrench.

Remove the clutch drum.

Clean and lubricate the shaft with molybdenum grease.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

Check the washer wear and if it is necessary replace it.

Removing the clutch drum, pay attention to the two roller

gages into the pinion.

Check, clean and lubricate with molybdenum grease the

two roller cages every two hours of engine operation.

ATTENTION:

If you don’t do this operation, you can SERIOUSLY

DAMAGE THE CRANKSHAFT.

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USER MANUAL TECH F1 R Rev 3- 22/03/08

Check the clutch springs every 15 hours of engine operation.

To dismount – replace clutch springs , see service manual

To avoid holes clutch facing damages, the clutch pins have to

works always with molybdenum grease.
Pay attention when use petrol to clean the engine, because
the pins grease could go away.

Before remounting the clutch drum, check, clean and

lubricate the pinion axis gear (Bendix).

Begin this operation dismantling the cover pinion axis gear.

Tightening torque: 10 N·m (1 Kg·m) [7 lbf·ft]

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USER MANUAL TECH F1 R Rev 3- 22/03/08

Clean the PINION ASSY GEAR (Bendix) only with

compressed air and lubricate it with molybdenum
grease.

Do not use solvent or petroleum to clean the pinion axis

gear, because in this way you take away its internal
lubricant.

ATTENTION: when you are starting the engine, in

order to avoid device damages, it is advised to
make short drives and to make sure itself that the
battery is loads. Also an improper use of the
carburetor choke can cause harmful hits .

Afterwards clean and lubricate with molybdenum grease the

cover pinion axis gear very well.

Remounting all the components.

FUEL PUMP

The fuel pump is actuated by the pulsating pressure changes in the plastic inlet manifold, and the pump will
transfer the fuel from the fuel tank to the carburetor.

ATTENTION: Before run the engine, check every time the right pipe connection between fuel pump and
plastic inlet manifold and the connection between fuel pump and carburetor.
Pay attention to possible petrol transuding

CARBURETOR

The standard carburetor calibration is for ambient temperature of 25° Celsius and sea level of 400 met ers.
At operation with different temperatures and altitudes the main jet of the carburettor may be changed to optimize
the engine performance.

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ATTENTION: new calibration can cause damages.

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ENGINE START OPERATION

Before run the engine check the following:

☺ Fuel tank full

☺ Oil tank full
☺ Radiator full of water
☺ Oil pipes connected in right position
☺ Water pipes connected in right position
☺ Battery charged and connected
☺ Carburetor Bowden Cable easy moving and carburetor piston connected in idle position
☺ Circuit Gasoline pipe connected and fuel of gasoline
☺ Inspect any part prone to wear (tyres, drive chain, bearings, etc.) before each kart event

At the engine start proceed as follows:

 On a cold engine pull the choke level in vertical position

 Put the switch in ON position
 Press start button (max. 5 sec. ) until the engine starts running. If the engine won’t start repeat starting
procedure after few seconds.
By pressing the start button the circuit between battery and starter motor will be closed. The starter
motor drives the starter gear on the crankshaft via an intermediate gear with free wheeling (bendix) until
the engine starts to run.
 After engine start take back choke slowly until engine idles smoothly without choke.

STOPPING THE ENGINE

 Run at minimum RPM the engine for 15 sec and put the switch in OFF position

ENGINE RUNNING-IN PROCEDURE

To obtain the longest possible life span of components the engine has to be subject to a defined running-in
period at first operation of engine or after overhauling engine.

 Start the engine and run the kart in the truck for 15 minutes at continuously changing load and engine
speed fluctuation must not go beyond to 8.000 r.p.m.

 Afterwards run the kart for 15 minutes with load and speed changes up to 10.500 r.p.m.

 After this running-in time the full power of the engine may be used

ENGINE PARKING AND TRANSPORT

The go kart with installed engine has not to be placed in vertically position . Max angle position from the ground
40° degree.

ATTENTION The Oil inside the engine go slowly into the combustion chamber : possible damage!

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OPERATING LIMITS

LIMIT OPERATION

Max. engine speed r.p.m.

13.000
An electronic speed limiter prevents engine speed in excess of 13.000 r.p.m

Min. coolant temperature [°C] 65

Max. coolant temperature [°C] 90

Min. oil temperature [°C] 70

Max. oil temperature [°C] 110

Inlet valve clearance [mm] 0,10 – 0,13

Exhaust valve clearance [mm] 0,15 – 0,18

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