TILLOTSON T4 User manual
Tillotson T4 User Manual
Introduction:
Congratulations on purchasing a Tillotson T4 Kart package! This document has been prepared to
offer information on all items from building the new kart to maximising the performance from the
equipment. It will advise on many aspects including the following:
Kart Build
Starting the Engine
Engine Running-In Procedure
Chassis Setup
Tyre Pressures
225RS Engine
Engine Safety Precautions
Engine Specification
Engine Recommendations
Torque Values
T4 Oil / Lubricants
Carburettor Setup
Kart Preparation
Event Preparation
Necessary Tools
Competition Check List
Troubleshooting
T4 Optional Items
Kart Build:
Items Required:
Tillotson T4 Kart Package x 1
Kart Trolley x 1
Tools:
Spanners / Wrench Sizes: 8mm, 10mm(x 2), 13mm(x 2), 16mm, 17mm
Socket Sizes: 8mm, 10mm, 13mm, 22mm
Allen Key Set: 3mm, 4mm, 5mm, 6mm, 8mm
Measuring Tape
Snips
Laser Alignment Tool / Tracking Discs: For front end tracking geometry
Straight Edge Ruler / Laser Sprocket Aligner: For setting the position of sprocket so chain is aligned
Tyre Mounting Paste / Soap / WD-40: For Mounting Tyres
Impact Gun / Spark Plug Stopper: For Mounting Clutch
Compressed Air: For Popping Tyres onto Rim
Flat section of timber / any material: For Seat fitting
Fuel / Fuel Funnel
Tie Wraps
Loctite
Steps to Take:
Take all items from the T4 packaging and identify each item supplied
It is recommended to start by fitting the axle first. Mount the Rear Axle fitting the Sprocket Carrier
and Brake Disc in Correct position and ensure the axle is fitted the correct orientation so the keyway
lines up to the brake disc / sprocket carrier and not in reverse.
Measure the Rear Axle so it is centered in the chassis and tighten the 3 x grub screws in the Axle
Bearing Carriers (2 of them). It is recommended to fit using Loctite as these grub screws can come
lose on a bumpy track.
Set the position of the two Rear Hubs. Recommended Rear width with wheels mounted is 139-
140cm. Insert photo.
Mount the side and front rails followed by the KG bodywork using the bolts and springs provided.
Mount the rear Bumper Section using the bumper kit supplied.
Mount the Steering Column, Steering Wheel and Nasseau Panel brackets.
Mount the Stub Axles (Central Position) and Steering Track Rods.
Mount the front hubs and fit one large spacer on the inside as a starting position (10mm). Insert
photo
Track the front-end geometry
Mount the Brake Cable to Caliper
Mount Tyres to Wheels and pump until Popped. Set Pressures in the recommended range from 12-
18Psi.
Mount the seat. Cable Tie a flat section of Timber or another material to be underside of the frame
so the seat is resting on the timber. This makes the bottom of the seat flush and level to the lower
chassis rail. It is possible to mount it higher or slightly lower in extreme cases however it is not likely
to last long where there is large kerbs as the seat will drag along the track easily.
Factory Recommendation for a driver sizes 5ft 6” – 6ft:
From Front Chassis Rail to Front Of Seat RHS: 63cm
From Rear Axle to Crown of the Seat: 20cm
Engine Assembly:
Mount the exhaust by tightening the two 13mm Nuts first / then insert the bolt and spacer to
tighten the exhaust support arm. USE LOCTITE ON BOTH STUDS AND SUPPORT BOLT.
Mount Clutch using impact gun or with a 13mm socket with a spark plug stopper so to tighten the
clutch sufficiently.
Mount the inlet Manifold. USE LOCTITE ON BOTH STUDS.
Mount Tillotson HW Carburettor: check Jet Settings using the Tillotson Quickjet tool.
L: 2T
H: 1T
Mount Air Filter
Fill Engine with 500mL of Tillotson Racing Oil
Mount the Engine Mount to the base of the 225RS engine.
Engine Now Ready for Assembly to Kart:
Fit Engine and align the rear sprocket to the front sprocket using a Laser Alignment Tool or straight
edge ruler.
Lock the Rear Sprocket Carrier in Position and Mount the Chain.
Set the appropriate Chain Tension.
Mount the chain guard supplied and fasten via the supports provided.
Fit the outer and inner throttle cable from the chassis to the carburettor – check that the accelerator
pedal is hitting the cable stop so it will not stress the throttle cable and confirm you are reaching full
throttle from the carburettor.
Fit the fuel line from the fuel tank to the carburettor. Also it can be advised to mount an option in-
line fuel filter which are available such as the Tillotson FS-1 filter
Ensure the overflow bottle from the fuel tank has a hole drilled to vent the fuel tank.
Mount Tyres
Fit the Tillotson Racing Decals to the T4 Kart using heat gun if necessary to soften the material
Double check each nut and bolt is tight
Fill with Fuel
Proceed to Running-in Procedure for the Engine.
Starting Procedure:
It is necessary when the engine has not been running to set the choke in the On Position and pull the
starter chord until the fuel has reached inside the carburettor. Alternatively, with the air filter
removed you can cover the inlet with your hand and pull the starter chord until fuel arrives to the
venturi of the carburettor.
At this stage the engine should be ready to ignite. It may be necessary to open the throttle lever on
the carburettor to help with the engine start.
When the engine is running through the day it should not be necessary to use the choke mechanism
however if the engine is not starting it is advised to set the Choke in the On Position and pull two
times and then release again.
It is important that the spark plug is not coked up with carbon otherwise this will affect the engine
starting so it can be necessary to clean the spark plug / fit a new one to avoid starting issues when
the plug has had a lot of use.
Running-In Procedure:
The running in procedure for the engine is a very important element in the engine life. If care is not
taken when running in the engine, then it can shorten the life of the engine dramatically.
Start the engine on the Kart Stand and warm up the engine for 3-5minutes but not revving the
engine to high rpms without load.
For the first 10 minutes, drive moderately at varying speeds up to 4,500-5,000rpm. It is important to
vary the RPM for proper camshaft, piston rings and component break in.
Stop and allow the engine to cool, check that there are no fuel or oil leaks.
For the second 10 minutes, drive moderately at varying speeds from 5,500-6,200rpm. Again, stop
and allow the engine to cool.
For the final 10 minutes it is necessary to drive at race speed so increase to the maximum 6,500rpm
(Wide Open Throttle).
Once you have completed the running-in procedure it is important to change the oil. This is to
remove any metal particles which could arrive from the new components in the engine. Drain the oil
when hot so it can easily transport any particles.
Re-fill 500mL of Tillotson Racing oil into the engine and you are race ready.
Tillotson T4 Chassis
The chassis has been designed specifically to suit the Tillotson 225RS engine with user friendliness in
mind and to provide great handling performance. Only stock components will be allowed in the T4
Series in order to maintain the low cost for the category including Seat, Axle, Wheels, etc.
Adjustments can be made to the kart as per any normal category however only using the stock parts
and it is fitted with a caster camber system as standard.
In order to obtain the optimum performance from the kart in all conditions it can be necessary to
make fine adjustments to the setup of the kart throughout the race weekend. The track conditions
can change each session due to more grip being applied to the track or if weather conditions are a
factor and the track condition is not stable. There are many ways to alter the setup of the kart to
improve the performance which will be outlined. Note: the optimum kart setup for each driver will
vary due to driving style, weight distribution (height of driver / lead on kart), condition of tyres, etc.
Front-End Setup:
How to Add More Front-End Grip:
1. Widen the front width of the wheels by adding spacers. Standard setting is with one large
10mm spacer.
2. Raise front of the chassis using spacers on the stub axle.
3. Add positive caster to the front stub axle.
4. Reducing rear end grip can make the front end more positive.
5. Alter the position of the track rods on the steering column - the lower the mounting the
more positive the steering.
Conditions to add more Front End:
When there is minimal tyre wear and kart is not as positive on entry into corners.
On a tight track where the front end of the kart needs to be reactive.
On a green, damp or wet track where the track condition is not good and the kart is less
responsive / understeering.
How to Remove Front-End Grip:
1. Narrow the front width of the wheels by removing spacers.
2. Lower the front of the chassis using spacers on the stub axle.
3. Remove caster on the front stub axle.
4. Adding rear end grip can push the front end and cause understeer removing front end grip.
5. Alter the position of the track rods on the steering column - the higher the mounting the
less positive the steering.
Conditions to reduce Front End Grip:
When tyre is brand new and very positive on steering
On a wide track where less steering input is required
On a high grip track
When the driver is aggressive on turn on this style will suit less front end grip
Rear-End Setup:
How to Add more Rear-End Grip
1. Narrow the width of the rear hubs on the axle
2. Use optional seat stay from seat mounted to the bearing carrier on the axle
3. Lower the rear axle (raise the chassis) – not highly recommended only in extreme conditions
Conditions to add Rear-End Grip:
On a green track, or in damp / wet weather conditions
If you need to increase rear end traction
If front end is too reactive and the rear end is stepping out
How to Remove Rear-End Grip:
1. Widen to width of the rear hubs on the axle to the max. permitted length at 140cm
2. Raise the rear axle (lower the chassis) – not highly recommended only in extreme conditions
Recommended Seat Position:
Factory Recommendation for a driver sizes 5ft 6” – 6ft:
From Front Chassis Rail to Front Of Seat RHS: 63cm
From Rear Axle to Crown of the Seat: 20cm
It is possible to alter this seat position for a very small or larger driver so the seating position is more
comfortable. The max range recommended is from:
From Front Chassis Rail to Front Of Seat RHS: 58-66cm
Tyres Pressures:
Maxxis Sport T4 Slicks:
This tyre is a medium compound which is extremely durable. The recommended window for this
tyre is from 12Psi – 18Psi. The occasion to run lower tyre pressures would be in very hot track
conditions or for a very long race so the tyre will not drop off a lot during the race.
The time to run higher pressures will be in cold conditions or in damp weather so it is necessary to
generate as much tyre heat as fast as possible so the tyre will work.
Maxxis Sport T4 Wets:
The wet tyre is a soft rain tyre so care needs to be taken so not to overheat the tyre from new. The
recommended window can range from 10Psi – 20Psi depending on how wet the track is and also
how abrasive the surface of the track is. Here is a typical recommended guide for setting the tyre
pressures in wet conditions:
Damp: 10-12Psi
Wet: 12-16Psi
Heavy Rain: 16-20Psi
Stock Recommended T4 Kart Setup
Front Width: 10mm
Caster / Camber: Neutral
Front Chassis Height: Middle (Neutral)
Steering Track Rod Position on Steering Column: Middle
Rear Width: 139cm – 140cm
Rear Chassis Height: Middle (Neutral)
Optional: No seat stays mounted
Tyre Pressures Slicks: 12-18Psi depending on temperature and track conditions
TPP225RS Engine:
Engine Specification
F
eature:
Specification
Engine
Tillotson 225RS, 2 Valve, 4 Stroke, Single Cylinder
Fuel Type
Unleaded Petrol
Bore x Stroke (mm)
72 x 56mm
Displacement (cc) 225cc
Required Oil Capacity Min
500mL
Oil Type Tillotson Racing Oil by
XERAMIC® Kart Lubricants
(*only oil
permitted)
Cooling System Air
Carburettor
Tillotson HW
-
46A 20mm venturi
Compression Ratio 9:1
Ignition System
PVL Digital Ignition limited to 6,500rpm
Flywheel
Billet flywheel digital ignition type 31
°
Advance Timing
Connecting Rod Billet Aluminium with Bearing inserts 88mm length
Camshaft
Max Lift Race Cam with built in Compression Release
Cylinder Head 2 Valve OHV
Horsepower
15HP Peak
Engine Weight Dry
16kg
Clutch
Dry Shoe Clutch
Exhaust System
RLV
Silencer
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