Tomberlin CrossFire 150 User manual

CrossFire 150
Service Manual

TABLE OF CONTENTS
Model Identification.................................................................................................................................................1
Starting the Engine...................................................................................................................................................1
Break in Procedure...................................................................................................................................................2
Checks and Services.................................................................................................................................................3
Engine Oil................................................................................................................................................................4
Final Gear Oil...........................................................................................................................................................5
Spark Plug................................................................................................................................................................5
Battery......................................................................................................................................................................6
Air Filter.................................................................................................................................................................10
Torque Chart...........................................................................................................................................................11
Valve Clearence Inspection....................................................................................................................................12
Valve Mechanism Inspection and Servicing..........................................................................................................13
Cylinder Head Removal/Installation......................................................................................................................13
Camshaft................................................................................................................................................................14
Cam Chain..............................................................................................................................................................17
Rocker Arm and Rocker Shaft...............................................................................................................................18
Valve and Valve Spring..........................................................................................................................................18
Cylinder..................................................................................................................................................................23
Piston......................................................................................................................................................................24
Crankcase and Crankshaft Removal......................................................................................................................26
Crankshaft Inspection............................................................................................................................................27
Crankshaft and Crankcase Installation..................................................................................................................28
Lubrication System................................................................................................................................................29
Oil System..............................................................................................................................................................30
Transmission Diagram...........................................................................................................................................32
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Transmission..........................................................................................................................................................33
CVT Mechanism....................................................................................................................................................37
Drive Belt Pulley....................................................................................................................................................38
Clutch.....................................................................................................................................................................39
Driven Belt Pulley..................................................................................................................................................40
Transmission Belt...................................................................................................................................................42
Carburetor...............................................................................................................................................................42
Chain and Axle.......................................................................................................................................................48
Rear Axle Removal................................................................................................................................................48
Rear Sprocket Removal.........................................................................................................................................49
Axle Bearing Removal...........................................................................................................................................49
Swingarm...............................................................................................................................................................49
Charging System....................................................................................................................................................50
Ignition System......................................................................................................................................................54
Electrical Starting Mechanism...............................................................................................................................58
Armature Inspection...............................................................................................................................................59
Carbon Brush Inspection........................................................................................................................................59
Starter Motor Installation.......................................................................................................................................59
Starter Clutch.........................................................................................................................................................60
Reduction Gear Inspection.....................................................................................................................................60
Engaging Mechanism.............................................................................................................................................61
Brakes....................................................................................................................................................................62
Rear Brake Inspection............................................................................................................................................63
Front Brake Inspection...........................................................................................................................................65
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Brake Bleeding Fluid Change................................................................................................................................66
Rear Brake Disk Removal......................................................................................................................................66
Front End Adjustments...........................................................................................................................................67
Adjusting the Shocks.............................................................................................................................................68
Wiring Diagram.....................................................................................................................................................69
Notes......................................................................................................................................................................70
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MODEL IDENTIFICATION
VIN NUMBER
The vehicle identification number is stamped on a plate welded to the frame behind the driver’s seat.
ENGINE NUMBER
The engine number is stamped in the block below the left hand engine cover (directly in front of the oil drain
plug). It can also be found on the barcode decal located on the left hand engine cover.
VIN Number Location Engine Number Location
STARTING THE ENGINE
• Always wear a helmet and other essential safety gear while using the go-kart.
• Get in the kart slowly. Do not jump in.
• Fasten safety harness.
• Adjust seat position to comfort using the lever under the driver’s seat.
• Flip green ON/OFF switch to ON position.
• The foot brake must be depressed while attempting to start the go-kart.
• With brake still depressed, start the engine by turning the key clockwise.
Note: Engine will not turn over unless brake pedal is depressed.
• To immediately stop the engine -- flip the green ON/OFF switch to the OFF position.
WARNING
• The exhaust pipe, muffler, and heat shields are very hot during and after operation. DO NOT touch them until
they have cooled.
• The engine exhaust from this product contains chemicals known to cause cancer, birth defects, or other repro-
ductive harm.
• Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness and /or death.
Avoid prolonged inhalation.
1

BREAK-IN PROCEDURE
• 0-10 hours of operation
Do Not accelerate past half (1/2) throttle for long periods of time.
Do Not operate the machine at one continuous throttle. Vary the throttle during operation. Allow the
engine to cool for ten minutes after each hour of use.
• 10-20 hours of operation
Do Not accelerate past three-quarter (3/4) throttle for long periods of time. Vary the throttle during
operation and avoid maximum acceleration. Allow the engine to cool for ten minutes after each 1.5
hours of operation.
• After 20 hours
Vary acceleration while driving. Do Not use full throttle for long periods of time. Allow the engine to
cool occasionally during long periods of operation.
• Change the engine oil after the first 5 hours of operation. Please reference the table in this manual for
suggested oil change times after the break-in process.
2

PERIODICAL CHECK AND SERVICES
The maintenance intervals in the following table are based upon average riding conditions. Riding in unusually
dusty areas require more frequent servicing.
Items
Initial
Service
Daily
Monthly
Quarterly
Yearly
Tire Pressure
Inspect
Inspect
Chassis
Inspect
Inspect
Fasteners
Inspect
Inspect
Brake Performance
Inspect
Inspect
Brake Fluid
Inspect
Air Filter
Change
Carburetor
Inspect
Inspect
Spark Plug
Change
Drive Chain
Inspect
Inspect
Inspect
Adjust
Engine Oil
Replace
Inspect
Replace
Gearbox Oil
Inspect
Replace
Valve Clearance
Adjust
Fuel Line
Inspect
Inspect
Inspect
Exhaust
Inspect
Inspect
Battery
Inspect
Inspect
Interval
(Months)
Service
Date
Service Performed By:
Type of Service
1
3
6
12
18
24
30
36
42
48
54
60

MAINTENANCE AND TUNE-UP PROCEDURE
This section describes the servicing procedures for each item in the Periodic Maintenance requirements.
ENGINE OIL
API Classification SF – SG (SAE 15W – 40)
It is important to inspect the engine oil before each period of operation. The engine oil should be changed every
50 hours.
CHECKING THE ENGINE OIL:
• Place unit on flat surface.
• Remove dipstick and wipe off with a clean cloth.
• Return the dipstick to the hole. Push the dipstick in until the threads prevent it from going any farther.
Do Not screw the dipstick into place while attempting to check the oil. Doing so will cause a false
reading.
• Check oil level to see if it is between min and max indicators.
• Add oil as necessary to reach the required level.
- Return the dipstick to its original position. Be sure to tighten the cap into place after checking the oil.
CHANGING THE ENGINE OIL:
• Run unit for at least 5 minutes or until warm, shut off.
• Place suitable container for draining oil beneath engine.
- Container should be capable of holding at least 1 gallon.
- Warning - Engine components may be hot. Use caution while attempting to change the oil.
• Remove the engine drain plug, oil filter cap, spring, and oil filter screen. Drain the oil completely.
• Check condition of O-ring and filter screen for foreign material before re-installing.
• Install the drain plug and torque to 12 ft. / lbs.
• Fill with 25 to 31 oz. of API classification SF – SG (SAE 15W – 40) oil.
• Start engine and check for leaks.
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• Shut off engine and check the oil level with dipstick, do NOT screw the dipstick in when taking this
reading, doing so may cause a false reading. Add oil if necessary to reach safe amount; Do Not overfill.
FINAL GEAR OIL
Inspect final gear oil level monthly and change final gear oil according to the chart on the previous page..
• To check level, remove level screw on the left rear engine case. If gear oil does not come out of the
hole, add gear oil until it begins flowing out of the hole.
Drain plug
• To drain gear oil, remove the drain plug at the rear bottom of the engine case. It is recommended to
warm the engine for 10 minutes or more before attempting to drain final gear oil. Warning - Engine
components will be extremely hot after the kart has been running. Use extreme caution when working
on an engine that has been in use.
Note:
API Service Standard GL-5, GL-4, GL-3 SAE 80W 90 gear oil is recommended in the final drive case. How-
ever, in extreme cold weather conditions it is advised that a lighter viscosity oil, such as 75 weight oil be used .
Final drive capacity:
115 cc 4 oz.
SPARK PLUG - NGK C7HSA
• Clean up the carbon around the spark plug to prevent the carbon from dropping into the cylinder when
removing the spark plug.
• Remove the spark plug.
- Clean up carbon accumulation on the spark plug with a steel brush or a blade.
- Inspect the spark plug gap. The gap should have a measurement between the intervals given below.
Spark plug gap: .024 in. ~ .028 in. (0.6 ~ 0.7mm).
Note: If the carbon accumulation and wear on the spark plug appear to be excessive, replace it using a spark
plug with the same specification.
5

FILLING THE BATTERY
The following procedure should only be performed by an adult utilizing extreme caution. While attempting this
procedure, individuals should wear rubber gloves, eye protection, and have water available in case the
electrolyte solution comes into contact with skin or eyes. Children should not attempt to complete this
procedure, and should NOT be allowed near the area when attempting to fill the battery. This procedure should
be completed first so that the battery is charged when the kart assembly is complete
WARNING
: POISON - CAUSES SEVERE BURNS
Contains sulfuric acid. Avoid contact with skin, eyes, and clothing.
To prevent accidents, rinse the empty electrolyte solution container
with water after use.
- If solution comes in contact with the skin, flush the area with
water.
- If solution is swallowed contact a physician immediately.
- If solution comes in contact with the eyes flush with water for
fifteen minutes. Get immediate medical attention.
KEEP OUT OF REACH OF CHILDREN
PROCEDURE
- This procedure should be performed in a location out of reach of children and animals.
- Remove the battery and the electrolyte solution from the shipping crate.
- Place the battery on a level surface and remove the metallic sealing from the top.
- Holding the electrolyte container upside down so the sealed openings are facing the ground, align each sealed
opening of the bottles with the corresponding openings on top of the battery terminal.
- Strongly push the electrolyte container into the openings of the battery terminal so that the all of the seals on
the electrolyte container break, allowing electrolyte solution to flow into the battery. Do NOT attempt to
puncture the electrolyte container unless the six sealed openings are properly aligned with the six openings on
the top of the battery terminal.
- Air bubbles will begin rising from each opening of the electrolyte solution when they are punctured.
- If air bubbles are not rising in each individual tube, tap the top side of the electrolyte bottles.
- Leave the electrolyte bottles in their draining position until all of the electrolyte solution has drained. Do
NOT attempt to remove the electrolyte bottles while they are draining.
- Do NOT attempt to puncture or cut any part of the electrolyte container.
- Do NOT allow children near the battery at any point during the installation process.
- When the electrolyte solution has finished draining, pull the bottles gently from the top of the battery terminal
and properly discard in a location out of reach of children or animals.
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