[tony zambos]

Are they absolutely needed, no.  Parts 9 & 10 are a means to adjust the throttle cable. You might have an adjustment screw similar to part 10 at the chassis tab where the sheath for the throttle cable ends with a nut to prevent it from turning.  The concern would be the tube that is attached to the carb top is threaded on the inside to accept this adjuster and might wear the throttle cable if not in place.

[tony zambos]

You’re welcome

[tony zambos]

 

Eric,

the most common problem is one of the leads to the motor brushes is broken within the starter. Would have thought you have measured voltage between the wire running to the starter and ground if it was a brush problem.  The starter is easy enough to repair. A set of new brushes, a couple of screw drivers, two alligator clips and a little RTV is all thats needed.  This link will get you a video:http://www.youtube.com/watch?v=W-1ftV1dMNg#t=19.  There are other ways of holding the armature in place while putting the can back on, but the vice grip does work.  You might consider a getting a spare starter for the future.  Good luck

 

 

 

 

[tony zambos]

John,

Start with going to a kart shop. If you can, bring the radiator with you.  The caps are pressurized with a fitting for an overflow line

[tony zambos]

This should help:

http://www.aimsports.com/support/manuals.html

 

[tony zambos]

Eric, still think that if you have the bearings out, replace them. Experiment with the worst one and save the other for an emergency.  If that bearing seizes while you’re in a corner, it’s going to snap your kart right around.

[tony zambos]

Bill,

Can’t argue with the AIM SmartyCam. A great choice.  But with some extra work, you could use a MyChron and a GoPro Camera.  For software you’ll need RaceStudio and at least Race Render.  If your pc is running less the Window7, Race Render will only be able to create a Windows version of the output. If you need to create versions of your video for a Mac, MPEG format, I used Media Conveter 8. The nice feature of Media Converter 8 is that it can create videos that can be played on any device, ie smart phones, iphones, tabelets, what ever.

Race Render has a free trail version that’s good for making a short video.  If you already have a MyChron and a GoPro, you could download the free version and play with it. What you are going to find is that it takes a bit of  patience in syncing the video and the data. That something you wouldn’t have to worry about with the SmartyCam.  Race Render allows you to use either one of their gauge templates or you can create your own.  You’ll need a GPS receiver if you want the track map if your using Race Render with a GoPro.

[tony zambos]

Kirt,

There are probably several posts on the EKN Classic forum about servicing bearings.  This is the first one I came across.  http://eknclassic.com/viewtopic.php?t=118637&highlight=bearing

If you can afford new ones, buy them.

 

[tony zambos]

Dave,

Brake cleaner will do that to paint.  For stripping the chassis, use a chemical paint stripper designed to remove paint form aircraft.  Years ago, it was available at Auto Zone.  Don’t know about now.

[tony zambos]

For now-BOTH!.  Assuming that you are transporting the kart horizontally, this should not be happening unless pressure is building up in the tank.  Pull the carb off. Check for the floats being installed properly and there isn’t any fluid in them.  The “alto” stamped on the floats should be facing up when the carb is in its operating position. You should be able to hear them rattle when you shake the carb up & down. Also check the needle valve for debris that could be preventing from shutting the fuel supply off or maybe the needle and seat just needs to be replaced do to wear and age.

[tony zambos]

DT,

A happy new year back to you.  Have never seen this on a Mychron gauge, but have seen a good number of displays gone bad.  It could be either the display itself, the chip driving the display or a broken connection.  If it was my gauge, first step would be to contact AIM.

http://www.aimsports.com/support/index.html

 

[tony zambos]

Eric,

No expert here on CRG brakes, but the pads should have worn fairly evenly from top to bottom. It seems that the lower pistons in both calipers are not functioning correctly.  Suggest that you take one apart for inspection.  After you remove the caliper from the chassis, but before removing the brake line, slowly pump the pistons out about 3/8 of an inch.  That will make it easier to get the pistons out later.  Check for worn or hard seals, and for damage to the pistons and their cylander walls.  Even if all looks well, new pistons and seals wouldn’t be a bad idea.  And for sure, replace all of the brake fluid.  If not comfortable doing this, have your kart shop make the repairs.

P.S. Replace the pads

 

[tony zambos]

Since you’re new to the sport, I’d start with a visit to your local kart shop. It’s a good time of the year to get acquainted with the shop owner. Have him look at the motor and carb so you’ll have a dependable power plant to start with. With an older motor, you should concider the upgrade to the new style clutch.  As far as tuning the motor, you will need some basic knowledge of the power valve and how to jet the carb.  Below is a link to a tuning manul for a CRG.

And you should concider some software and a guage.  Mychron gauges  are common and you can download your data into Race Studio for analysis.  Race Studio is free to download.  At some point my wish to purchase jetting software.  I’ve only used Jet-Tech and will recommend it.

Also you will need pen and paper.  Take notes on weather and track conditions, plus chassis setups.  Good luck and you might want to bring a buddy with you to the track.

http://www.crg-america.com/pdfs/CRG_Kart_Tuning_Manual.pdf

http://www.rotaxjetting.com/     (jetting swoftware)

[tony zambos]

Any kart shop or retailer should have pulse line.  Keep it as short as possible without any kinks

[tony zambos]

Just a thought that the bendix might be  hanging up on occassion.  With the ring gear about four times the size of the bendix, the engine turning 3k would have the starter spinning at 12K.  We’re rooting for you.  Good luck and keep us posted.

[tony zambos]

Jim,

one last try.  Has the bendix ever been replaced?

[tony zambos]

Jim,

Took apart a Leopard starter motor. Between any of the ten contacts, got about .7 ohms.  A couple of ideas. First, the insulation on the windings is melting do to extreme heat.  Possible causes could be too much current to the starter or maybe a poor ground.  Taking one of your busted starters apart and see if it smells like an electrical fire.

The other possibility for the failure could be physical damage.  I’ll guess, since I have no proof, that if the motor was spinning without a load, that it could tear itself apart.  Could your starter motor still be running after the engine starts and the bendix has disengaged?

 

[tony zambos]

Jim,

That sounds very unusual.  No ideas, but a couple of questions.  When you find the bad commutator, are you replacing just the commutator or the whole starter? And where, if you don’t mind, are you purchasing the replacement parts?

[tony zambos]

Jeff,

for several years now, we’ve run with 15 min for the 4 cycles, 25 min for sprinters, and 40 min for the laydowns. Hope you can make it up here.

 

[tony zambos]

To the best of my knowledge, once you have calibrated your barometer, leave it alone. Make a note on which recording weather station you used and the altitude you used in the calibration setup.  Double check your settings when you replace the batteries in the gauge.

 

[tony zambos]

The post for the video says RaceRender 2.7.3.  A couple minor of things, but you should be aware of.  You will have to export your logger data.  The documentation is good and available on the RR web site. See http://racerender.com/RR2/Features.html. For the option to display the track map, you will need a GPS unit. Pay attention to the bottom of the web page for the output formats.  No problem for a pc usable type output, but if you have a pc running earlier than Win7, but will not be able to create an MPEG (Mac) formatted file. But there is software available to do that.  The time it take to generate a video will depend on your pc.  For me, a thirty minute vid takes 4-6 hours.  Something for your pc to do while you’re at work or asleep.

For mounting to your fairing, use the top half of the roll bar mount. Looks the same as the  handle bar mount, but thicker material.

[tony zambos]

Greg,

Does it make a difference what cylinder you have on now a day?  We had two cylinders, one had ports that were WKA legal and another with TaG USA legal ports.  The engine turned more than 1K in RPM’s with the WKA cylinder at road race events.

[tony zambos]

No longer running a Leopard.  Had the old push button type ignition.  14K is what we got out of it.

[tony zambos]

Many years ago, used a chemical paint stripper designed to remove paint form aircraft purchased from an auto parts store.  Many not be able to buy anything that strong any more.  If I would do it now, would take it somewhere and have some sort of media blaster remove the paint.

 

[tony zambos]

The gut feeling is no.

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