Carter Talon 150 FX Series User manual

Talon 150 GX/FX/DLX Series
Service Manual

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FOREWORD
This service manual has been specially prepared to provide all the necessary information for the
proper maintenance and repair of the DLX/FX/GX.
The DLX/FX/GX fits the needs of a wide variety of kart users above 16 years old. Those who will
be servicing this kart should carefully review this manual before performing any repair or services.
All information, illustrations photographs and specifications contained in this manual are based on
the latest product information available at the time of publication. Due to improvements or other
changes, there may be some discrepancies in this manual. Therefore, if newest information is
requested in the future, please contact the local distributor.
Distributor reserves the right to make production changes at any time, without notice and without
incurring any obligation to make same or similar changes to vehicles previously built or sold.
Carter Brothers
1871 U.S. Highway 231
Brundidge, AL 36010
Tel: [phone]
Web: http://www.carterbro.com

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GENERAL INFORMATION 1
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 5
ENGINE 9
LUBRICATION SYSTEM 24
FUEL SUPPLY SYSTEM 28
TRANSMISSION COMPONENTS 33
ELECTRICAL STARTING SYSTEM 36
BELT DRIVE CVT MECHANISM 42
CLUTCH 46
REAR TRANSMISSION SYSTEM 51
ELECTRICAL SYSTEM 56
IGNITION SYSTEM 62
CHASSIS 66
WIRING DIAGRAM 72
INDEX 73
TABLE OF CONTENTS

1
GENERAL INFORMATION
MODEL IDENTIFICATION
FRAME NUMBER
The frame number or VIN is stamped under the seat on the frame cross member and on a sticker
behind the seat.
ENGINE NUMBER
The engine number is located on the lower front left side of the engine case.
FUEL AND OIL RECOMMENDATIONS
Be sure to use the specified fuel and oil.
FUEL
Gasoline should be 85 to 95 octane or higher.
Unleaded gasoline is recommended.
ENGINE OIL
A high-grade 10W-40 motor oil should be used.
BREAK-IN PROCEDURE
• For the first 2hours of riding, do not exceed 2/3 throttle.
• Vary engine speed for the first 5 hours.
• Never hold engine at full throttle for long periods of time.

2
SPECIFICATIONS
DIMENSIONS
Overall length 2075mm (87.7 inch)
Overall width 1235mm (48.6inch)
Overall height 1400mm (55.1inch)
Wheelbase 1450mm (57inch)
Front Track 1060mm (47.1inch)
Rear Track 1000mm (39.4inch)
Ground Clearance 130mm (5.1inch)
ENGINE
Type Forced air – cooled 4 strokes
Engine capacity 150cc
Bore x stroke 57.4 x 57.8
Corrected Compression Ration 9.2: 1
Carburetor PD25J
Output Power 9HP/7500rpm
Maximum Torque [N.m(r/min)-1] 8.0/4000-4500
Starting Electric
Ignition CDI
Lubrication Force & Splash
Transmission Automatic CVT
CAPACITIES
Load 1 rider or 90kg/198Ibs
Fuel tank 7L/1.54Gal
Starting 5s
Climbing 20-25°
CHASSIS
Front Brake Hydraulic disc/left foot control
Rear Brake Hydraulic disc/left foot control
Front Tire 19 x 7.0-8
Rear Tire 18×9.5-8 or 22×10-10
Suspension-Front Dual A-arm with 1.8” (45mm) of travel
Suspension-Rear Spring over shock with 2.4”(60mm) of travel
Brake Track 7m@20miles/h
Top Speed 30miles/h(or limited as customers require)

3
WEIGHT
Dry Weight 155kg/341lbs
TIRE PRESSURE
Front 2.9Psi (20kPa/cm2, 0.2kgf/cm2)
Rear 2.2Psi (15kPa/cm2,0.15kgf/cm2)
WARRANTY
Parts & Workmanship 6 months
* The specifications are subject to change without notice.

4
LOCATION OF PARTS

5
PERIODIC MAINTENANCE
AND TUNE-UP PROCEDURES
PERIODICAL CHECK AND SERVICES
The maintenance intervals in the following table are based upon average riding conditions. Riding in
unusually dusty areas requires more frequent servicing.
Items Needing
Servicing
Initial Service
(first week)
Monthly Quarterly Yearly
Tire pressure/wear I I
Brake performance I I
Tightness of screws I I
Air cleaner C C I
Carburetor I A C
Spark plug C, A
Drive chain I I C, A, L
Brake fluid I
Replace gearbox oil I R
Chassis C, L L
Fuel switch/fuel tank C
Battery I I
Engine oil R
Valve clearance of engine A
A: Adjust C: Clean I: Inspect, clean or replace if necessary L: Lubricate R: Replace
MAINTENANCE AND TUNE-UP PROCEDURE
Descriptions of the servicing procedures for each item in the Periodic Maintenance requirements.
SPARK PLUG
• Clean up the carbon around the spark plug to prevent it from dripping into the cylinder when
being removed.
• Remove the spark plug
• If the spark plug is too tight to remove, spray rust inhibiter on the spark plug washer and the
thread. After soaking for a few minutes, the spark plug should easily unscrew.
• Clean up any dirt and carbon accumulation on the spark plug with a steel brush or a blade.
• Inspect the spark plug gap, it should be about 0.6 ~ 0.7mm.
• When the carbon accumulation and wear of the spark plug are too severe, replace the spark plug
with one of the same specification.
Note: The spark plug should generally be serviced when the engine is cold.

6
TIRE PRESSURE/WEAR
Check the tire pressure every time the kart is ridden. The tire pressure is very important for the
stability of the ride.
Tire Pressure
Front 2.9 psi 20kPa/cm20.20kgf/cm2
Rear 2.2 psi 15kPa/cm20.15kgf/cm2
BRAKE PERFORMANCE
• Always check that there is plenty of brake fluid in the brake fluid reservoir.
• Check that the rear brake pads are in good condition.
• Check the brake rotor for abnormal wear.
AIR CLEANER
If the air cleaner is clogged with dust, performance will be severely decreased and if left unser-
viced, engine damage can occur. Check and clean in the following manner.
Paper Filter Maintenance
• Remove the air cleaner from its housing
• Tap filter on a hard object to knock dust from the filter
• Replace the element if it is wrinkled or torn
Foam Filter Maintenance
• Remove foam filter from steel cage
• Wash in non-flammable cleaning solvent
• Submerge in oil and squeeze to remove excess oil
• Install the element back into the air box.
Note: Clean after every 20 hours of use, or more often if used in a dusty environment.
Caution! Before and during cleaning, inspect the element for
tears. A torn element must be replaced. Make sure the element
is seated proplerly and no foreign material can pass by.