Installation and tips to get started with your new KGP Junior engine:
1. Gear Oil
If the “Fill oil yellow label” is attached to the engine oil plug – remove it – unscrew the gear oil bolt and put 30ml of light gear oil into the balance shaft chamber as per the instructions in the engine box.
2. Charging and using the Freeline Lipo Engine starter battery.
Before using the engine the Lipo battery must be fully charged up. The Lipo battery must be charged inside Freeline battery case using the supplied battery charger. Select setting Lipo CHARGE 2.6a 16.8V charge rate series 4.
Never leave the battery charging unattended. Remove the red blanking cover on the side of the battery and using with the short red wire extension with white connectors on each end plug one side into the battery and the other into the series 4 port on the balance charger. Connect the ‘freeline power lead’ from the battery into the charger. (Check the picture below for your reference
If the Lipo battery voltage ever drops below 13v one of the battery cells may fail and the battery will not be able to accept a charge. In this case “Low Voltage” will appear on the screen – this means the battery is dead and cannot be recovered – a new battery would then be required.
When attaching the battery to your kart you must mount it on the left hand side of the seat as per MSA regulations using the freeline battery support provided. It is obligatory in the KGP regulations to use the Freeline extension power lead. The battery can no longer be mounted on the electric panel.
Remember to switch off the power after every session and disconnect the battery at the end of each days running. Always charge the battery prior to a test day or race weekend.
3. Fuel Mixture:
The mix ratio is 20:1. (5Ltrs petrol 95 or 97 unleaded to 250ML of Formula KGP 2 stroke oil only).
4. Starting carburettor settings:
When mounted on the engine the jet closest to the engine is the low jet. Turn clockwise until it stops. Then using a clock face as an example as a setting turn the low jet anti clockwise and set at 65 mins.
The jet further away from the engine is the high jet. This jet is concealed behind a silver blanking screw. If you remove it the small fixed main jet is screwed in behind it. The main jet sizes available are stamped 83, 85 or 87.
We recommend that you start with jet size 87 – this is a medium to rich setting to start off in dry running. Fine adjustment on the low jet and perhaps a different selection of the fixed main jet may be needed for better engine performance.
PLEASE NOTE: close the low jet too much and you could risk piston seizure!
In heavy rain we suggest the fixed high jet 83 and adjust and run the low jet at 50 mins as this will give better acceleration on the exits of the corner. PLEASE NOTE: As the track gets drier and you go quicker you may need to return the low jet back to the dry setting – if you don’t a risk of piston seizure could occur.
5. Fill the water system up
Connect all hoses and then fill the radiator with water until full. Lift the radiator side of the kart and spin the rear axle to activate the water pump attached to your axle. Top up again the radiator up again when the kart is level.
6. Water temperature
Best temperature is between 45c to 52c max. If it is a cold day maybe blank some of the radiator so that the engine gets up to temperature.
7. Check the water system for any leaks
Making sure all jubilee clips are tight and that the radiator cap is closed and secure.
8. Throttle Cable
Make sure the throttle cable functions properly and that the pedal touches the stop. We would recommend that you fit a secondary carburettor return spring for safety.
9. Run in the engine for 15mins
Run in at no more than 13,000 rpm but making sure that sufficient load is put on the engine through the corners whilst taking it easy on the straights by lifting off around a ¼ way down a straight after a corner. We advise using the spark plug NGK 9 EGV whilst running in as this is a hotter plug and should not oil up whilst running in at lower speeds.
10. Never run the engine on the trolley
This can damage the engine and is against MSA regulations
11. Take care out the pits!
After running in and every time you enter the track always ensure you take 1 to 2 laps for the engine to get up to temperature before going full rpm to allow the water temp to rise.
If the day temperature is less than 12c or it is wet conditions then use the spark plug NGK9EGV.
With a day temperature of 13c + we would recommend using the spark plug BMB LS10 or any of the NGK 10 spark plugs listed in the KGP technical regulations.
12. Once run in and normal lap speed is being achieved the best maximum RPM range is between 15200 rpm and 16200 rpm.
13. Drain the water out of your engine and kart at night
It’s better to remove the water and take the engine off the kart at the end of the day. In the winter it’s really important as you never know it may freeze! This would damage your cylinder.