Complete KZ engine overhaul

TKART Staff

20 January 2017

Every so often, shifter engines need to be completely overhauled. It is quite a long and complex operation and should be performed by an experienced specialist or... By following the instructions of dr tkart

time 120 min

difficulty Hard

It is physiological: after an elevated number of laps on the track, even a kart engine wears. Therefore, every now and then, it needs to be completely overhauled in order to assess the condition of its internal parts and replace any that are too far gone.
A truly complete overhaul includes the replacement of the piston and checking the transmission gears, two operations which not only require the engine to be removed from the kart (also removing all liquids such as water and transmission oil), but also entirely disassembled or, as they say in the jargon, you need to “open it up”. Basically... you need to know your way around. In this article, “Dr TKART” shows you how it’s done on an IAME Parilla shifter unit. However, the operations are much the same for the majority of shifter engines.

NECESSARY TOOLS

■ OTHERS: sealing paste, cutter
■ APPROPRIATE PULLERS AND WRENCHES
■ SEEGER PLIERS
■ MALLET WITH PLASTIC ENDS
■ 17 MM, 14 MM, 12 MM FIXED WRENCH
■ 4 MM, 5 MM, 6 MM COMBINATION WRENCH

STEP

15 MIN

Having removed the engine of the kart, as mentioned, the first step is to completely remove clutch, coil and primary transmission carter. Immediately afterwards, unscrew the six screws of the reed valve pack, slide it off, then use a 12 mm wrench to unscrew the four nuts that secure the cylinder to the crankcase. At this point, gently remove the cylinder, being careful not to allow the piston and connecting rod to knock against the crankcase.

TO FIND OUT MORE

This article does not provide a detailed description of the steps required to remove the clutch, coil and primary transmission carter, which are explained step by step in the “primary transmission and clutch” article, also on the “Dr TKART” channel