Trouble Shooting Guide for Clutch Kart Engines
Working at SwedeTech and answering the customer technical questions, I’ve been able to compile quite a list of troubleshooting tips. Most of the knowledge comes from direct hands on experience from the three of us in the shop. Feedback from customers also allows me to stay current with the engines that are used in karting throughout the world.
The information in this article will hopefully help you when the time arises. For all of us that have spent any amount of time at the track, some of these problems will sound familiar. This guide is created with a clutch or direct drive engine utilizing a pumper style carburetor in mind. So, I will quit blabbering with ‘fill content’ and get started.
Engine Does Not Show Spark
- Before trying to restart the engine, always inspect the inside of the engine utilizing an inspection light. This can be done by removing the spark plug and looking inside the cylinder with the inspection light. Look for any damage on the piston or cylinder walls. If you see damage, do not run and consult your engine builder, preferably SwedeTech.
- Replace the spark plug and set the gap to the engine builders recommended specification.
- Check that the spark plug cap is snug fitting on the spark plug. You should feel resistance of the rubber gripping the spark plug as you lift on and off. If you see black graphite looking material on the porcelain, replace the plug cap. This is caused when the cap is ‘floating’ up and down on the spark plug. On most engines, the spark plug cap is screwed onto the spark plug wire. Some other plug caps use a pin that pierces the plug wire and the conductor.
- Make sure your plug cap is properly connected to the plug wire. To do this, hold the plug wire firmly and give the spark plug cap a solid pull. The cap should not come off with a snug pull. If it does come off, inspect the end of the plug wire and look for burnt or frayed conductor wire. Cut off approximately ¼” of the plug wire and install the plug cap. If the plug cap feels tight on the plug wire insulator, you can apply a small amount of WD-40 to help minimize the resistance while screwing on. The WD40 will absorb and will provide a secure connection.
- Check all wire connections on the coil, stator plate, and all other wire harness items. Look for cut, burnt or pinched wire insulation. Unplug all wire connections and inspect the connection points.
- Look for any damage on the coil, stator, or flywheel. Some ignition systems will fail to work if the stator or pick up unit takes a direct hit from track debris or an object.
- Before trying to restart the engine, always inspect the inside of the engine utilizing an inspection light. This can be done by removing the spark plug and looking inside the cylinder with the inspection light. Look for any damage on the piston or cylinder walls. If you see damage, do not run and consult your engine builder. You will frequently see this statement in this guide.
Engine Performs As If It Starving for Fuel
- Before trying to restart the engine, always inspect the inside of the engine utilizing an inspection light. This can be done by removing the spark plug and looking inside the cylinder with the inspection light. Look for any damage on the piston or cylinder walls. If you see damage, do not run and consult your engine builder.
- Make sure the fuel tank has proper venting to the atmosphere. If you are using a catch tank on the vent line, make sure the catch tank is properly vented. On most karting applications, supply, return, and venting fuel line connections with an I.D. of 3/16” (4.8mm) should be adequate for proper fuel supply and venting. Always inspect all fuel line connections, especially on the inside of the plastic tank connections. Any obstruction inside the fuel line or connections will cause fuel supply issues.
- Always run a fuel filter inline before the carburetor and/or fuel pumps. If you think a fuel filter is causing a restriction, find a better one that will not cause a fuel restriction. Carburetors do not perform properly when they are filled with debris.
- Inspect fuel lines for holes, debris, pinched or restricted bends, and overly tightened zip ties. If you are using zip ties to secure the fuel line, remove them and use hose clamps or safety wire that is wrapped twice around the line before you tighten. Zip ties will cause the hose to unevenly secure the fitting, and in some cases will cause an air leak. The zip tie does not form a full circle with such small diameter tubing. The fuel line should never have kinks or pinches in them. Make sure all suction side of fuels lines are secured with safety wire or hose clamps. Sometimes the damage on the fuel line can be noticed if you flex and move the line around.
- Inspect carburetor gaskets for damage or wear. Inspect filter screen for any debris, even the smallest pieces of lint. Inspect carburetor hard parts for cracks or damage.
- Check the carburetors pop off pressure and the fulcrum arm height. These specifications will vary from each engine builder, so consult with them for the proper numbers.
- Check the gasket between the carburetor and intake manifold/cylinder. Make sure the pulse circuit is unobstructed with a gasket or misalignment. Check the pulse line for obstruction, damage, cuts, or loose fittings.
- Before trying to restart the engine, always inspect the inside of the engine utilizing an inspection light. This can be done by removing the spark plug and looking inside the cylinder with the inspection light. Look for any damage on the piston or cylinder walls. If you see damage, do not run and consult your engine builder.
Trouble Shooting Guide for Clutch Kart Engines
Working at SwedeTech and answering the customer technical questions, I’ve been able to compile quite a list of troubleshooting tips. Most of the knowledge comes from direct hands on experience from the three of us in the shop. Feedback from customers also allows me to stay current with the engines that are used in karting throughout the world.
The information in this article will hopefully help you when the time arises. For all of us that have spent any amount of time at the track, some of these problems will sound familiar. This guide is created with a clutch or direct drive engine utilizing a pumper style carburetor in mind. So, I will quit blabbering with ‘fill content’ and get started.
Engine Does Not Show Spark
- Before trying to restart the engine, always inspect the inside of the engine utilizing an inspection light. This can be done by removing the spark plug and looking inside the cylinder with the inspection light. Look for any damage on the piston or cylinder walls. If you see damage, do not run and consult your engine builder, preferably SwedeTech.
- Replace the spark plug and set the gap to the engine builders recommended specification.
- Check that the spark plug cap is snug fitting on the spark plug. You should feel resistance of the rubber gripping the spark plug as you lift on and off. If you see black graphite looking material on the porcelain, replace the plug cap. This is caused when the cap is ‘floating’ up and down on the spark plug. On most engines, the spark plug cap is screwed onto the spark plug wire. Some other plug caps use a pin that pierces the plug wire and the conductor.
- Make sure your plug cap is properly connected to the plug wire. To do this, hold the plug wire firmly and give the spark plug cap a solid pull. The cap should not come off with a snug pull. If it does come off, inspect the end of the plug wire and look for burnt or frayed conductor wire. Cut off approximately ¼” of the plug wire and install the plug cap. If the plug cap feels tight on the plug wire insulator, you can apply a small amount of WD-40 to help minimize the resistance while screwing on. The WD40 will absorb and will provide a secure connection.
- Check all wire connections on the coil, stator plate, and all other wire harness items. Look for cut, burnt or pinched wire insulation. Unplug all wire connections and inspect the connection points.
- Look for any damage on the coil, stator, or flywheel. Some ignition systems will fail to work if the stator or pick up unit takes a direct hit from track debris or an object.
- Before trying to restart the engine, always inspect the inside of the engine utilizing an inspection light. This can be done by removing the spark plug and looking inside the cylinder with the inspection light. Look for any damage on the piston or cylinder walls. If you see damage, do not run and consult your engine builder. You will frequently see this statement in this guide.
Engine Performs As If It Starving for Fuel
- Before trying to restart the engine, always inspect the inside of the engine utilizing an inspection light. This can be done by removing the spark plug and looking inside the cylinder with the inspection light. Look for any damage on the piston or cylinder walls. If you see damage, do not run and consult your engine builder.
- Make sure the fuel tank has proper venting to the atmosphere. If you are using a catch tank on the vent line, make sure the catch tank is properly vented. On most karting applications, supply, return, and venting fuel line connections with an I.D. of 3/16” (4.8mm) should be adequate for proper fuel supply and venting. Always inspect all fuel line connections, especially on the inside of the plastic tank connections. Any obstruction inside the fuel line or connections will cause fuel supply issues.
- Always run a fuel filter inline before the carburetor and/or fuel pumps. If you think a fuel filter is causing a restriction, find a better one that will not cause a fuel restriction. Carburetors do not perform properly when they are filled with debris.
- Inspect fuel lines for holes, debris, pinched or restricted bends, and overly tightened zip ties. If you are using zip ties to secure the fuel line, remove them and use hose clamps or safety wire that is wrapped twice around the line before you tighten. Zip ties will cause the hose to unevenly secure the fitting, and in some cases will cause an air leak. The zip tie does not form a full circle with such small diameter tubing. The fuel line should never have kinks or pinches in them. Make sure all suction side of fuels lines are secured with safety wire or hose clamps. Sometimes the damage on the fuel line can be noticed if you flex and move the line around.
- Inspect carburetor gaskets for damage or wear. Inspect filter screen for any debris, even the smallest pieces of lint. Inspect carburetor hard parts for cracks or damage.
- Check the carburetors pop off pressure and the fulcrum arm height. These specifications will vary from each engine builder, so consult with them for the proper numbers.
- Check the gasket between the carburetor and intake manifold/cylinder. Make sure the pulse circuit is unobstructed with a gasket or misalignment. Check the pulse line for obstruction, damage, cuts, or loose fittings.
- Before trying to restart the engine, always inspect the inside of the engine utilizing an inspection light. This can be done by removing the spark plug and looking inside the cylinder with the inspection light. Look for any damage on the piston or cylinder walls. If you see damage, do not run and consult your engine builder.
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