Carter CBM 6.5 H.P. - 196cc Owner's manual

Owner’s / Operator’s Manual
Please Read This Manual Carefully Before Opeating This Engine!
It Contains Important Safety & Operating Information.
CBM 6.5 H.P. - 196cc
Part #7613-0001
4 Stroke – Air Cooled
Electric Start / Rope Start
General Purpose Gasoline Engine
Carter Bros. Mfg. Co., Inc.
1871 U.S. Hwy. 231
Brundidge, Al. 36010
[phone], Option #2
www.carterbro.com
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!*! WARNING!*!



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
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1. ENGINE BREAK-IN:
Read the Owner’s Manual prior to operation. Observing the Engine
Break-In Period is CRITICAL to the longevity of your kart’s engine.
A. For the first 0 to 10 hours;
1. Never operate at full throttle and avoid continuous
operation above half throttle.
2. Allow a cooling off period of 5 to 10 minutes after
every hour of operation. This can be accomplished
by cruising your Kart at slow speeds.
3. Vary the speed of the machine as you ride, but do
not exceed half throttle.
B. From 11 to 20 hours:
1. Avoid prolonged operation above ¾ throttle.
2. Do not use full throttle and continue to observe the
cooling off period.
C. Above 20 hours during break-in period:
1. Avoid prolonged full throttle operation.
2. Vary speeds occasionally.
3. Each full throttle operations MUST be followed by a
substantial cooling off period by cruising 5 to 10
minutes at slow speeds (low RPM).
2. AIR FILTER MAINTENANCE:
A. The air filter must be cleaned or replaced on a regular basis,
at least every 10 to 20 hours. Do this more often if the kart is
operated in very dusty areas.
B. Your air filter is the lifeline to your engine... improper
maintenance can result in engine failure!
Observing proper engine break-in
periods and continued cleaning of
the air filter is critical to the longevity
of your kart’s engine.
4
l. GENERAL
Thank you for purchasing a CBM (Carter Bros. Mfg. Co.)
brand engine! Please carefully read this manual before operating
this engine. It contains operating and safety instructions as well
as necessary maintenance information.
CBM brand general purpose gasoline engines are of the
highest quality and have the advantages of easy starting,
reliable power output, efficient fuel consumption, little running
noise and vibration, low displacement, multi power fan-out type,
and excellent after sale service system to let you use without
worry.
This series of gasoline engine adopts single cylinder, four
stroke forced air cooling, OHV25°incline, bottom place camshaft,
transistor non-contact ignition and reliable oil warming system.
It is small in size, light in weight and compact in structure.
This manual includes CBM gasoline engine series latest and
most timely operation and service information (drawings in this
manual do not completely represent actual parts and are only for
reference purposes). It simply provides guidance for your
operation of CBM engines. Since the product is being improved
continually, the gasoline engine will be subject to modifications
and improvements without prior notice or obligation.
Please read this manual carefully before operating, and
strictly operate according to the instructions located in the
manual. Our gasoline engine is very reliable and safe when
operated as designed. By not following the instructions in this
manual while operating this engine you may encounter personal
injury and / or property damge.
II. APPLICATION RANGE
CBM general purpose gasoline engines, being used as a
power source, are ideal for generators, water pumps, mini-tillers,
pressure washers, log splitters, go-karts, mini bikes, & various
other applications but, are not designed for motorcycles and
automotive applications.

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III. IDENTIFICATION
1. FUEL TANK
2. HIGH TEMPERATURE DECAL
3. OIL DIPSTICK
4. CRANK SHAFT FAN OUT
5. MUFFLER
6. AIR CLEANER
7. FUEL TANK COVER
8. CYLINDER HEAD COVER
9. CARBERATOR ASSEMBLY
10. STARTER
11. STARTER GRIP
IV. SAFETY NOTES
Don’t operate when you are tired, ill or under the
influence of alcohol.
This may result in serious
injury!
SAFETY MEASURE
The operators must be specially trained. Any person who is
not qualified to operate the gasoline engine are strictly
forbidden to operate this gasoline engine.
During the operation of the gasoline engine, the exhaust gas
contains some compound of CO (carbon monoxide) and CH
(content keeping within standard). In order to avoid
accidents, the engine must NOT be used indoors. If it has to
be used indoors, the exhaust gas must be led to the outside
of the building and the outlet of the guide pipe must be at
least 5 feet from the doors & windows, meanwhile, the air in
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the room must be free from inhibition.
For your and others safety, please pay attention to all safety
labels:
The engine and exhaust system
becomes very hot during operation and remains hot for up to
one (1) hour after stopping. Contact with hot engine components
can cause burn injuries and can ignite some materials.
Keep gasoline out of reach of children.
Don’t allow to place flammable, explosive and any other
dangerous substances around the engine to avoid fire.
The work area must be well ventilated. The fuel source must
be kept no less than 35 feet away from the engine. Also, the
engine must be located up-wind of the fuel source.
When filling with fuel or engine oil the engine must be in the
OFF position & not running.
Strictly prohibit smoking while filling with fuel. Do NOT allow
fuel or engine oil to overflow. If the fuel or engine oil
overflows, or leaks, thoroughly clean up the substance
before the engine is started.

You MUST fill the engine with the appropriate type and
amount of lubricating oil BEFORE starting the engine.
Failure to do so will result in engine damage and is NOT
covered under warranty. We recommend a quality brand of
10W-30 oil for most applications.
Skin irritation and possible skin cancer can
result from extended contact with gasoline. Thoroughly wash
contact areas of skin with water and soap.
Carefully protect the environment when disposing of gasoline
and oil. You should send it to the waste product station in your
area in a sealed container.
Do NOT dispose of gasoline or oil in trash or drain / sewage
system – this is very dangerous and is also a crime to do so.
It is best to keep engine level when draining oil – ONLY drain oil

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when engine is warm but, NOT hot. This will enable all of the oil
to drain properly while preventing burns to your skin.
V. SPECIFICATION
Model
Description
ZS160F ZS168FA ZS168FB ZS173F ZS177F ZS182F ZS188F
Bore x stroke 60×42 68×45 68×54 73×58 77×58 82×64 88×64
Displacement cm³ 118 163 196 242 270 337 389
Compression
ration 8.5

 

1 8.5

 

1 8.5
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 

1 8.2
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 

1 8.2
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 
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1 8
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
1 8
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1
Fuel consumption
ratio 395g/(kw.h) 374g/(kw.h)
Lubrication
consumption ratio 6.8g/(kw.h)
Idle speed r/min 1600±150
Valve gap Inlet

 

0.10—0.15mm Outlet

 

0.15—0.20mm
Noise accordance with GB15739-1995
Noise limit
Test according to GB/T1859-2000
Max.power &
speed
Kw/(r/min) 2.5/3600 3.2/3600 3.8/3600 4.85/3600 5.5/3600 6.8/3600 7.4/3600
Max. torque
and speed
N.M

 

r/min

 

6.2/2700 8.8/2500 10.7/2500 13.9/2700 15.8/2700 20.1/2700 22/2500
Mode of
ignition and
starting
Transistor magnet ignition and recoil hand- pull starting. Can successfully
start within 30s in the 268K-313K environment temperature.
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VI. SPECIFICATION 2
VII. OPERATION
1 PREPARATION AND CHECK PROCEDURES BEFORE
OPERATION.
Figure 7-1
E NV IR ON M EN T T EM P ER ATV R E

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ENGINE HAS NO OIL – YOU MUST FILL
BEFORE STARTING ENGINE!
Check engine oil level:
Unscrew the oil dipstick to check whether the engine oil is
within the range of specified limit. If the oil level is too low,
add the engine oil using the fill hole until the specified level is
reached.
CAUTION: Using different brand / types of engine oil will
vary according to environment temperature. CBM recommends a
quality brand of SAE 10W-30 for most applications

 

1

 

Oil dipstick hole

 

2

 

Highest oil level

 

3

 

Lowest oil level
Figure 7-2
b. Check fuel level:
Open the fuel tank cover and check the fuel level. If the
level is too low, add the proper amount of fuel. The
recommended fuel is standard unleaded 87 octane gasoline.
Do NOT mix the gasoline with oil. Do NOT use gasoline with
trash or contaminants in it. Figure 7-3
1

 

Fuel tank
2

 

Fill hole
3

 

Red line for upper fuel level
c. Check air cleaner:
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 



 


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2 Stage Air Cleaner Element - Check to see if the paper air cleaner is
clean and that the foam cleaner element is free from dust. First using oil
bath air cleaner, filling clean machine oil level (oil level marked on the
outer case of oil bath air cleaner) should be flush with oil level of the air
cleaner outer case.
Clearly see safety and warning
decals before starting.
1

 

butterfly nut
2

 

air cleaner cover
3

 

butterfly nut
4

 

paper filter-element
5

 

foam filter element
6

 

gasket
7

 

cleaner base plate
Figure 7-4
2) Starting engine
a) Open the throttle switch, close the choke, & adjust the
throttle valve to proper position. First, slightly pull the
starting handle until you feei a little resistance, then pull
forcefully to start the gasoline engine.

4

1) throttle switch 2) open position of the throttle switch
3) drain plug 4) pulling cable starter assy.
Figure 7-5
b) After starting, let the engine run for 1-3 minutes at idle speed,
meanwhile, check the engine working condition whether it runs
stable or smoothly and there is any abnormal noise, then open
the choke to maximum and adjust the throttle opening to obtain

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required speed. Operator must be present until the starting
process is completed.

 

1

 

choke

 

2

 

set choke to
off position
Figure 7-6
3) Stopping engine
When running engine, keep your self far away from the
muffler and don’t face exhaust outlet. Pay close attention to any
abnormal state of the engine while it is running. If you discover
any abnormal sound, vibration, serious traveling or back firing,
etc, Stop the engine at once.
Figure 7-7
Urgently stopping the
engine

 

Set the stop switch
to OFF position or directly pull off the spark cap.
To correctly stop the engine you: First remove load, allow
engine to idle for 2-3 minutes, then, set the stop switch to OFF
position.
Do NOT directly stop the engine without removing the load in
normal condition!
1) Throttle switch handle
2) Close position of the throttle
switch
3) Carburetor drain
Figure 7-8 4) Adjustment of the gasoline engine
(4)
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Each gasoline engine has been tested and inspected in our
factory> Generally, the engine will run without any adjustment.
Adjust to gasoline engine as needed by following procedure
below:
Feeler
Figure 7-9
Valve Rocker
Valve lock nut
Valve gap adjusting nut
For increasing valve gap, screw out the nut
For decreasing valve gap, screw up the nut
Figure 7-10
A. Adjust the valve gap: intake valve gap: 0.10—0.15mm;
exhaust valve gap: 0.15—0.20mm.
a. Grasp valve gap adjusting nut and release valve lock nut.
b. Turn valve gap adjusting nut to specified gap.
c. Grasp valve gap adjusting nut and screw up valve lock
nut. Torque: 10N.m (1.0kg.m)
d. After tightening up valve lock bolt, recheck valve gap.
B. Adjust the governor system (big and small tension spring,
throttle support, and throttle governor lever)
a. Remove the fuel tank.
b. Unscrew lock nut and move the throttle support to
completely open the valve.
c. After moving the throttle support, open the valve and turn
the throttle governor lever in same direction to farthermost

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position where it can reach, tighten lock nut.
d. Check if throttle support and valve move smoothly.
e. Install the fuel tank.
Figure 7-11
5) Notes on unpacking
Check contents of package and place all contents in a stable and
safe place. Carefully check that the engine contains all items
listed in the manual.
.
If you have any question about the operation of this engine,
please consult with your local dealer.
Do NOT disassemble the gasoline engine by yourself within
warrant period! THIS WILL VOID YOUR WARRANTY!
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VIII. TROUBLE SHOOTING
Will not start or starting difficulty:
Phenome
Cause Solution
Spark plug
No gasoline
flowing out
after
unscrewing
drain screw
at the
bottom of
the
carburetor.
Pin valve
blocked
Clean or
replace
carburetor
Oil supply
normal, but
compressing
poor
Piston ring
worn
Spark plug
loose
Cylinder
head
leaking,
valve gap
or timing
wrong
Replace
Tighten
Clean,
reinstall
or
readjust
Igniting and
gasoline
Supply
normal
High
voltage
cable
contacting
with spark
plug poor
Stop switch
malfunction
or short
circuit
Machine oil
alarm
damaged
Eliminate
and
connect
Eliminate
Replace
Spark
plug
deposit
exists
Spark
plug gap
too big or
too small
Spark
plug
insulator
damaged
Clean
deposit
Adjust
to
0.7

 

0.8
Install
new
spark
plug
No
spark
at the
spark
plug
Other
Igniter
damaged
Flywheel
magnetic
force
week
Renew
igniter
Renew
flywheel

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Having
spark
at the
spark
plug
Compressing fine
Cylinder
fuel too
much
Fuel
poor,
having
water or
dirt
Remove
spark
plug, dry
and
screw in
Replace
with
new
fuel
Abnormal condition in running:
Phenomena Cause Solution
Speed or power
insufficiency

 

Choke not opening
Muffler ventilating poor
Moving part worn
Governor kit not reaching
optimum balance Igniting
energy too low
Valve gap too big
Cylinder head existing
carbon deposit
Open the choke
Replace the muffler
Check or replace
Adjust the
governor kit
Replace the igniter
or the flywheel
Adjust to specified
range
Clean the carbon
deposit
Speed variation
too big
Governor kit not reaching
optimum matching state
Wrong carburetor
Spark plug gap not correct
Adjust the
governor kit
Replace the
carburetor
Adjust the gap
Engine Speed
too fast Governor bar not pressing the governor slider tight or
governor slider off
Readjust or
assemble the
governor slider
Abnormal sound Incorrect valve gap
Cam gear damaged Adjust the valve gap Replace the camshaft
Pin valve sticking with dirt
Lightly tap carburetor or cleanCarburetor leaking
0-ring deformed Replace
If you still have issues after completing these steps please contact your local dealer
for assistance.
Trouble Shooting continued
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IX. MAINTENANCE
Daily maintenance:
Check the filter element of the air cleaner, remove the dirt
and foreign materials to keep the element clean.
Check the fastening nuts for tightness.
Check the lubrication oil level and fill if necessary. Do
NOT overfill.
After 25 hours of operation the air cleaner should be
replaced.
After 50 hours of operation the spark plug should be
replaced and adjust its gap to 0.7-0.8mm.
1

 

remove the spark plug 2

 

adjust spark plug gap
Figure 9-1
Check radiating fin and remove the dirt between them. Replace
the lubrication oil, unscrew the drain plug, tilt the engine slightly
and let the lubrication oil drain out. Tighten the drain plug and
fill in the new lubrication oil to the specified oil level.
CAUTION: Add correct oil type, the fill volume for ZS 160F ZS
168FA/B is 0.6L,for ZS173F, ZS177F, ZS182F and ZS188F is 1.1L.
1

 

Oil drain plug
2

 

Oil fill
3

 

Specified oil level
After every 100 hours of operation, the fuel tank and filter
strainer must be cleaned. Open the fuel tank cover, take out the
filter strainer and clean it with brush. Take off the fuel tank, clean
inside of the tank and remove any dirt and water attached on the
internal surface of the tank. Reassemble the tank and insert the
strainer, then fill with new fuel until the level reaches full.
0.7

 

0.8mm

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Every two (2) years, check the condition of the fuel line. If there
is any ageing, hardening or cracks, it must be replaced. Tighten
the replaced fuel line joints and check for leaks.
Perform maintenance before stopping use for long period of
time.
1. If the engine will not be used for a long time, it must be
maintained before it is stored:
A Take off the fuel tank, drain out all fuel and clean the dirt and
water inside of the tank. Open the fuel cock, unscrew the drain
plug at the bottom of carburetor, drain out fuel in carburetor
thoroughly, and then, screw the drain plug to original position.
B Remove the drain plug at the bottom of the crankcase and
drain out the lubrication oil in crankcase thoroughly, then
tighten the drain plug.
C Clean the outer surface of the gasoline engine with clean
cloth, remove the dirt and dust etc, then store the gasoline
engine in a clean and dry place that is well ventilated.
D Turn crankshaft and make the gasoline piston stop at its upper
limit position in order to avoid air entering in.
Disposing of waste oil: Please use a special container to
collect waste oil from gasoline engine and send to local waste
oil collection station for disposal. Do NOT pour in trash or
drain / sewage system.
X. TRANSPORTATION & STORAGE
Carefully handle in the loading and unloading, keep upright and
don’t incline. Strictly prohibit bumping and protect from water
in the transportation process. The gasoline engine should only
be stored in a clean, well ventilated, moisture free location.
Xl. WARRANTY
CBM warrants that your engine will be free from defects for
a period of One (1) Year for residential use & Ninety (90) Days for
commercial use from date of original purchase. This warranty
covers parts and labor and/or replacement of defective item.
This warranty does NOT cover incidental expenses such as
transportation costs, lost wages, abuse, neglect or costs incurred
to remove or replace engine on its application. There are no
express or implied warranties. For assistance please contact your
local dealer or call [phone], Option #2.
18
Please Complete Warranty
Registration Card on
Page 19 within 10 days of
purchase and return to
address or fax located on
card. Failure to do so will
void your warranty!

19
CBM Engine Warranty Registration Card
Card Must be completed and returned within 10 days of purchase.
In signing this document, the Purchaser acknowledges and agrees that
he/she has read the Owner’s Manual and that failure to do so voids all
warranties, both implied and expressed.
I certify that I understand all of the above warnings, warnings in the
Owner’s Manual, and that failure to obey these warnings could result in
death or severe injury.
________________________________#
7613-0001 _____________________________
Date of Purchase (mm/dd/yy) Model Number Serial Number
________________________________________________________________________
First Name MI Last Name
________________________________________________________________________
Street Address
________________________________________________________________________
City St Zip Code
________________________________________________________________________
Dealer Name Website Address
________________________________________________________________________
City St Zip Code
_______________________________________________________________________
Home Telephone Number Purchaser Signature
Please fill out this form and fax or mail it back to:
Carter Bros. Mfg. Co. – 1871 U.S. Hwy. 231 – Brundidge, Al. 36010
[phone] Fax ESULT IN DEATH OR SEVERE PE
Card Must be completed and returned within 10 days of purchase.
20
Carter Bros. Mfg. Co., Inc.
1871 U.S. Hwy. 231
Brundidge, Al. 36010
[phone] phone
[phone] fax
www.carterbro.com
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
All information & specifications were correct and factual
at time of printing, 11/08, and may be changed without notice
or subjecting Carter Bros. Mfg. Co., Inc. to any liability as we
are improving our products on a continual basis.
