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.

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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.

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CHASSIS NUTS AND BOLTS
Always pay attention to the karts nuts and bolts. Some loosening after use is a normal. Check to
ensure that all nuts and bolts are tight.
Torque Tightening Chart
Bolt Conventional Marked Bolt 8.8 Marked Bolt
Diameter N.m Kg.m Ib-ft N.m Kg.m Ib-ft
4 1 ~2 0.1 ~0.2 0.7 ~1.5 1.5 ~3 0.15 ~0.3 1.0 ~2.0
5 1 ~4 0.2 ~0.4 1.5 ~3.0 3 ~6 0.3 ~0.6 2.0 ~4.5
6 4 ~7 0.4 ~0.7 3.0 ~5.0 8 ~12 0.8~1.2 6.0 ~8.5
8 10 ~16 1.0 ~1.6 7.0 ~11.5 18 ~28 1.8 ~2.8 13.0 ~20.0
10 22 ~35 2.2 ~3.5 16.0~25.5 40 ~60 4.0 ~6.0 29.0 ~43.5
12 35 ~50 3.5 ~5.5 25.5 ~40 70 ~100 7.0 ~10.0 50.5 ~72.5
14 50 ~80 5.0 ~8.0 36.5 ~58 110 ~160 11.0 ~16.0 79.5 ~115.5
16 80 ~130 8.0 ~13.0 58 ~94 170 ~250 17.0 ~25. 123.0 ~181.0
18 130 ~190 13.0~19.0 94 ~137.5 200 ~280 20 ~28.0 144.5 ~202.5
FUEL SWITCH (PETCOCK)
• Periodically clean the petcock externally with grease remover and water.
• Check for any leaks or seeping fuel.
• Replace the petcock if there are any leaks found.
This vehicle has a manually operated fuel calve. There are three positions.
“ON” position
The normal operating position for the fuel valve lever is the “ON” position. In the position, fuel will
flow to the carburetor.
“RES” position
If the fuel level in the fuel tank becomes too low for the engine to operate with the fuel valve lever
in the “ON” position, turn the lever to the “RES” position to use the reserve fuel supply, and refuel
as soon as possible.
“OFF” position
The closing position for the fuel valve is the “OFF” position.
When the vehicle is not in use, always make sure the petcock is in the “OFF” position.
Note: Inspect the first week and then every month thereafter.

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FINAL GEAR OIL
• To check level, remove level screw on the
left rear engine case.
• To drain oil, remove the drain plug at the
rear bottom of the engine case. It is recom-
mended to warm the engine for 10 minutes
or more draining final drive oil.
Final drive capacity
80ml 80/90 weight
ENGINE OIL
• Remove the drain plug from the left side bottom of the engine.
Drain into oil pan for disposal.
• Remove the large cap on the right bottom of the engine and re-
move the screen.
• Wash the screen with cleaning solvent and refit, making sure the
O-ring is still in good condition.
• Refill the engine with 10W-40 engine oil and run for 5 minutes.
• Check oil level on the filler cap stick to assure proper level.
• The cap needs to be screwed in for a proper reading.
CHASSIS
Grease chassis bushings and bearings with grease quarterly to
assure smooth operation and extended lift of the bushings and the
components. If used in extreme wet and muddy conditions or dusty
conditions, greasing is recommended more often.
CARBURETOR
Refer to Carburetor section.
VALVE CLEARANCE
Refer to Engine section.
Note: Inspect monthly and change quarterly.
Note: 80/90 weight gear oil is recommended in the final drive case. However, in
extreme cold weather conditions, you may notice that the kart is hard to push. If
that is the case, use lighter viscosity oil, such as 75 weight or equivalent motor-
cycle transmission fluid.
Note: Inspect before each use. Change monthly.

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ENGINE
ENGINE COMPONENTS INSPECTION AND SERVICING
ENGINE COMPONENTS AND CRANK CONNECTING ROD
MECHANISM INSPECTION AND SERVICING
ENGINE COMPONENTS: CYLINDER
CYLINDER REMOVAL
The removal can be done on the vehicle body.
• Remove cylinder head.
• Remove cylinder.
• Remove cylinder gasket, bolts
• Erase cylinder gasket.
CYLINDER INNER WALL WEAR INSPECTION
Use a bore diameter dial gauge to measure the degree of wear.
The measure point is divided into three sectional planes in the axial direction: upper, middle and
lower; measure every plane each time on the mutually perpendicular directions (X, Y), the mea-
sured least dimension is the cylinder bore; at the most upper position measured is the largest
diameter, and the lowest position measured is the smallest diameter, their difference is the cylin-
dricity of the cylinder. At the same cross section, measured the difference of diameter between two
points mutually perpendicular; which is the circularity of the cylinder.
In the situation without a dial gauge, a feeler gauge can be used to make relativity measurement,
that is to put a new piston into the cylinder, and use the feeler gauge to measure the gap between
the piston skirt and the cylinder wall, then figure out the abrasion loss of the cylinder. If the circu-
larity of the cylinder exceeds the limit, then a cylinder reboring machine should be used to rebore
the cylinder, and enlarge its diameter by 0.5mm or 1.00mm, then fit the piston and piston ring
which size are also enlarged. If the wear is too severe and cannot be reworked, then a new cylin-
der should be installed.
Cylinder bore 57.4mm
Cylindricity 0.05mm
Circularity 0.05mm
Caution!
Do not damage the cylinder area. Make sure not to drop anything,
including cylinder gasker material into the crankcase.
In order to make the measuring point perpendicular with the bore axis of the cyl-
inder, and to ensure the precision of the measurement, the bar of the gauge can
be slightly swung in the direction of the gauge bar, and take the smallest reading
number as the result.

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CRANK CONNECTING ROD MECHANISM: PISTON SET
PISTON PIN INSPECTION AND SERVICING
• Insert the piston pin horizontally into the piston pin hole, and inspect the clearance between pis-
ton and piston pin.
Service Limit 0.02mm
If the free play is too much, the worn condition of piston pin and piston pin hole must be inspected
respectively.
• Measure the external diameter of piston pin.
Service Limit 14.98mm
If the result is less than the Service limit, it should be replaced.
After replacement, check the clearance between piston pin and piston pin hole and make sure it
complies with the required measurement.
• Measure the inner diameter of piston pin.
Service Limit 15.02mm
If the result is more than the service limit, it should be replaced.
After replacement, check the clearance between the holes of the piston pin and make sure it com-
plies with the required measurement.
PISTON RINGS INSPECTION AND SERVICING
• Inspect the piston ring for flaws, serious wear, or serious conglutination, etc. If there is, it should
be replaced.
• If the piston ring’s lateral clearance and notch clearance are too large or too small it will cause
malfunctions, so it must be measured.
• Measure the clearance of the piston ring in the piston ring groove. This clearance is the piston
ring’s lateral clearance.
First Ring 0.09mm
Second Ring 0.09mm
CONNECTING ROD END INSPECTION
• Put the piston pin and bearing into the connecting rod end; inspect the degree of tightness of the
piston pin in connecting rod end.
• Measure the inner diameter of the connecting rod end.
Service Limit 15.06mm
When the abrasion of the bore exceeds the limitation, it should be replaced.

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PISTON RINGS SET UP
Before setting up, apply oil on each piston ring, then enlarge piston rings; at the same
time put them on the piston and move downwards gradually, until piston rings fall into the
ring groove.
PISTON SET INSTALLATION
• Remove the gasket attached to the crankcase.
• Mount piston onto the small end of the connecting rod.
• Mount piston pin and piston pin clip
• Apply oil on the piston pin to lubricate it.
CRANK CONNECTING ROD SET
The connecting rod is the component that links the piston and crank.
The picture shows the structure and assembling relations of the crank
connecting rod component.
CRANKCASE AND CRANKSHAFT REMOVAL
Before removing the crankcase and crankshaft, follow these procedures:
• Remove the engine.
• Remove the cylinder cover.
• Remove the cylinder.
• Remove the piston.
• Remove the drive plate and the driven plate.
• Remove the AC generator.
• Remove the starting motor.
• Remove the oil pump.
• Then remove the cam chain tensioner bolt. Remove the
cam chain tensioner.
• Use special tools to remove the starting driven gear.
The top of the piston marked with “IN” should be mounted towards the direction of
the inlet port (if the mark is “EX”, then it should be mounted towards the direction of
the exhaust port).
Cover the crankcase port with a piece of cloth to keep the
piston clip from dropping into the crankcase.

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• Remove the crankcase positioning bolts.
• Separate the right crankcase and the left crankcase.
• Remove the gasket and the dowel pins.
• Remove the crankshaft from the crankcase.
• Take out the cam chain.
• Remove the gasket on the crankcase joint face,
be careful to not damage the joint face.
• Remove the oil seal from the left crankcase.
• Remove the oil seal from the right crankcase.
Be careful not to damage the joint face.

13
CRANKSHAFT AND CRANKCASE INSPECTION
Replace the whole set of the crankshaft if serious wear is found while inspecting. Measuring the
axial trend clearance of the big end of the connecting rod.
When measuring, put the large end of the connecting rod close to the crank, and insert the feeler
gauge between the other side and the crank, for the correct end play.
Service Limit 0.55mm
Measure the radial trend (X,Y) clearance of the big end of the connecting rod.
Service Limit 0.05mm
Measure the main shaft journal jump of the crankshaft.
If the crank journal jump is too much it will cause the engine to shake abnormally, and shorten the
lift of the engine, so it must be examined carefully when inspecting.
Service Limit 0.10mm(A=90)
0.10mm(B=105)
Examine if there is any loose, or unusual sound when the crank journal bearing turns, if there is,
the whole set should be changed.
After cleaning the crankcase, inspect if there is any damage.
Inspect if the joint face of the crankcase is smooth and clean, and notice if it will affect the sealing
performance between the left and right crankcase while reassembling.
After the above inspection, if the crankcase has some surface damage, use oilstone to refinish it.
If damage is too severe, replace the cover.
CRANKSHAFT AND CRANKCASE INSTALLATION
• Mount the crankcase oil seal.
• Put the cam chain into the left crankcase.
• Put the crankshaft into the left crankcase.
Because the right and left crankcase axle hole must be concentric, they
should be replaced at the same time.
Pay attention to avoid damaging the oil seal with the cam chain.

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• Mount the new dowel pins and gasket on the left crankcase. Then join the right crankcase and
left crankcase together.
• Tighten the crankcase positioning bolts.
Tightening Torque 1.98 lbs/m
• Mount the starting driven gear
• Mount the cam chain tensioner
• Mount the new O-ring on the cam chain tensioner bolt.
• Apply some oil on the O-ring.
• Tighten the cam chain tensioner bolt.
VALVE MECHANISM INSPECTION AND SERVICING
The picture shows the common valve train of a four-stroke engine. This is a kind of overhead valve
train, its intake port, exhaust port, cam shaft are all located in the cylinder head, the valves bottom up
over the combustion chamber.
GENERAL INTRODUCTION
The four-stroke engine completes its four stroke with one piston stroke.
• Intake stroke
• Compression stroke
• Expansion stroke
• Exhaust stroke
The O-ring must be mounted in the groove.

15
VALVE CLEARANCE ADJUSTMENT
Valve clearance is an important technical parameter in the
valve train. In order to make sure that during any condi-
tions, especially when the engine is overheated, or in cold
conditions a certain clearance must be kept. This clearance
is called valve clearance. When the engine is running, the
valve clearance must not be too big or too small. So, valve
clearance adjustment is an important procedure in the valve
train maintenance.
Remove the cylinder head cover.
Turn the cooling fan clockwise until the mark of the timing drive sprocket on the camshaft is at the
top, dead center, and the “T” symbol (or other mark) of the magneto flywheel aligns to the crank-
case mark.
When adjusting, loosen the lock nuts, adjust the bolts with
a valve-adjusting wrench when turned clockwise the valve
clearance decreases. And when turned counterclockwise
the valve clearance increases. Put a feeler gauge with spe-
cific sizes between the valve and rocket to check for correct
clearance.
Take out the feeler gauge, tighten the lock nuts, and then inspect the valve clearance again.
Valve Clearance 0.08 ~ 0.12mm
Inspection and adjustment should be done in
cool conditions (below 35oC).
The crankshaft should corotate, or the exhaust port may not be adjusted.
Sometimes when tightening the lock nuts the clearance will change,
so it must be rechecked for the proper clearance.

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CAMSHAFT
The camshaft is a main driving unit of the valve train. The air inlet cam, the exhaust cam, and the cam
journal are on the shaft. It controls the intake and exhaust valve to open and close at the correct time.
Wear to the camshaft will affect engine performance and cause excessive noise.
CAMSHAFT REMOVAL
• Loosen valve cover bolts and remove cover.
• Remove the cam chain tensional bolt cap, and remove the O-ring.
• Tighten the cam chain tensioner by adjusting bolt clockwise.
• Turn the flywheel counterclockwise to make the “ T” mark on the
flywheel align with the mark on the crankcase. When the hole on
the cam chain (timing drive chain wheel) is up, it should be at the
top, dead center.
• Remove the cylinder head positioning bolt.
• Remove the camshaft holder bolt cap and washer.
• Remove the camshaft holder and dowel pin.
• Remove the cam chain wheel from the cam chain, and remove the
camshaft.
CAMSHAFT INSPECTION
• Inspect the camshaft bearings for play, if there is replace the whole set.
• Inspect cam surface for damage.
• Measure the height of the cam.
Inlet Cam 25.96mm
Exhaust Cam 25.815mm