swissauto

! IMPORTANT NOTICE!

This engine is designed strictly for competition purposes only.

EVO2
The manufacturer SWISSAUTO declare that all spare parts and
engines are not covered by any warranty.
Only SWISSAUTO can recognize the manufactured defect after
control.

Assembly Instructions
and
The authoritative manual Operating Manual
in case of discrepancy is the
manual on the website
www.swissauto.com

31
 Contents
All indications and procedures described in this manual are up to date at the time
of publication and have been defined to the best of one’s knowledge, however
excluding any liability.
All rights reserved. Subject to technical modification. Errors expected.
Reproduction, translation or distribution of this publication, even in extracts, only
with prior written permission of:

Buchmattstrasse 46 - 48
3400 Burgdorf
Schweiz
www.swissauto.com

2 Scope of Supply

3 Installation onto the Go-Kart Customer’s name

14 Start-up

16 Maintenance Engine number

18 Special Tools

19 Recommended Accessories
Your official dealer
20 Tips and Tricks

21 Dismantling the Clutch

23 Assembling the Clutch

24 Wiring Plan

25 Basic Settings of the Carburetor

26 Table Main Jets

27 Table Gear Ratios

28 Table Tightening Torque

29 Technical Data
1 30
 Technical Data Scope of Supply
Engine 1 cylinder 4 stroke with balance shaft

Water cooled, water pump in engine block

Cooling
integrated

Engine casing Gravity die cast Aluminium

Cylinder Gravity die cast Aluminium with Nicasil coating

Bore / Stroke 75 / 56.5 mm

Displacement 249.6 ccm

35 / 39 HP at 10'000 1/min with 30 / 34 mm

Power
carburetor

Cylinder head 4 valves per cylinder, DOHC on roller bearings

Crankshaft Steel, forged, roller bearings

Piston Aluminium forged

● engine ‚swissauto 250’ with clutch, ignition and fuel pump
Connecting rod Steel, forged, mounted on roller bearings ● radiator
● radiator support with silent blocks, bolts and nuts
Lubricating system Integrated dry sump with diaphragm pump ● 2 cooler hoses
● 3 hose clamps 27.1
Ignition Digital battery ignition with rpm limiter ● 1 hose clamp 28.6
● carburetor
Carburetor Dell'Orto D = 30 mm / 34 mm ● carburetor rubber
● 2 hose clamps for carburetor rubber
Fuel pump Vacuum pump integrated into the engine casing ● air filter flange
● air filter incl. clamp
Gearless drive with centrifugal clutch and chain ● crankcase ventilation hose with ventilation tube 90°
Transmission
drive ● ignition coil with spark plug boot
Dimensions L/W/H = 410/190/330 mm ● battery box with battery, relay and cabling
● control unit
Weight 15 kg incl. starter ● 3 pipe clamps with bolts and nuts
● primary tube with gasket and nuts
Spark plug gap 0.6 mm ● exhaust silencer
● 2 silencer springs
Distance generator ● throttle cable (inner wire and sleeve)
1.2 mm to magnets
stator
● clamp for throttle cable

29 2
 Installation onto the Go-Kart Table Tightening Torque
Tightening Torque Thread Strenght Nm
Step 1: Complete the engine by assembling the ignition coil, the radiator
and the carburetor. Charge the battery!
Loctite
Engine mount allen screw 243 M8 8.8 22

Transmission sprocket bolt hexagon

with flange M6 8.8 13

Transmission sprocket nut hexagon M28x1 110

Clutch mount nut heaxagon M24x2 150

Spark plug A/F 16 M10x1 12

Mount the ignition coil as shown Generator-stator (coil) M6 8.8 10

on the cylinder head.
Mounting bolt for oil filter hexagon M14x1.5 26
Use the screw M6x40 with
washer and tighten with 10Nm.
Oil drain plug hexagon (magnetic) M14x1.5 26

CLUTCH:

Starter sprocket with clutch mount

hexagon M8 10.9 22

Starter sprocket with clutch mount

Insert the spark plug boot into hexagon M7 8.8 22
the plug hole and push it onto
the spark plug. M6
Starter sprocket with support ring allen stainless
screw steel 10

3 28
 Table Gear Ratios Installation onto the Go-Kart
Top Speed at 13'000 rpm

Transmission Rear Transmission Rear Bolt M8x80 with washer

sprocket sprocket Top Speed [km/h] sprocket sprocket Top Speed [km/h]
11 90 83.9 14 88 109.2
11 89 84.8 13 81 110.2
11 88 85.8 14 87 110.5
11 87 86.8 13 80 111.5 Self-locking flange nut M8
11 86 87.8 14 86 111.7
11 85 88.8 13 79 113.0 Tighten with 12Nm.
11 84 89.9 14 85 113.1
11 83 91.0 13 78 114.4
11 82 92.1 14 84 114.4
11 81 93.2 14 83 115.8 2x flange nuts M6
11 80 94.4 13 77 115.9
11 79 95.6 14 82 117.2 Silent block 20x10 M6x12/12
11 78 96.8 13 76 117.4
11 77 98.1 14 81 118.6
Tighten with 10Nm.
13 90 99.1 13 75 119.0
Avoid distortion of the silent block during
11 76 99.3 14 80 120.1 installation of cooler hose up.
13 89 100.3 13 74 120.6 Otherwise shorten the cooler hose
11 75 100.7 14 79 121.6 accordingly.
13 88 101.4 13 73 122.2
11 74 102.0 14 78 123.2
13 87 102.6 13 72 123.9
11 73 103.4 14 77 124.8
Radiator support
13 86 103.8 13 71 125.7
11 72 104.9 14 76 126.4 Bolt M6x16 with washer
13 85 105.0 13 70 127.5 Tighten with 10Nm.
13 84 106.2 14 75 128.1
11 71 106.3 14 74 129.9
14 90 106.8 14 73 131.6
13 83 107.5 14 72 133.5
11 70 107.9 14 71 135.3
14 89 108.0 14 70 137.3
13 82 108.8

27 4
Installation onto the Go-Kart Table Main Jets

Height above
>1000 800 500 300 0 sea level
Hose clamp 28.6
900 910 920 930 940 950 960 970 980 990 1000 1010 1020 1030 air pressure [mbar]

Cooler hose below 0 104 104 106 106 106 106 108 108 108 108 110 110 110 112

2 104 104 104 106 106 106 108 108 108 108 110 110 110 112

4 104 104 104 106 106 106 106 108 108 108 110 110 110 110
Hose clamp 27.1 6 104 104 104 106 106 106 106 108 108 108 110 110 110 110

8 104 104 104 104 106 106 106 108 108 108 108 110 110 110

10 104 104 104 104 106 106 106 106 108 108 108 110 110 110

12 102 104 104 104 106 106 106 106 108 108 108 108 110 110
Cooler hose up
14 102 104 104 104 104 106 106 106 108 108 108 108 110 110

Air temperature [°C]

16 102 104 104 104 104 106 106 106 106 108 108 108 110 110

18 102 102 104 104 104 106 106 106 106 108 108 108 108 110

2x hose clamps 27.1 20 102 102 104 104 104 104 106 106 106 108 108 108 108 110

22 102 102 104 104 104 104 106 106 106 106 108 108 108 110

24 102 102 102 104 104 104 106 106 106 106 108 108 108 108

26 102 102 102 104 104 104 104 106 106 106 108 108 108 108

28 100 102 102 104 104 104 104 106 106 106 106 108 108 108

30 100 102 102 102 104 104 104 106 106 106 106 108 108 108

32 100 102 102 102 104 104 104 104 106 106 106 108 108 108
Squeeze all 4 hose clamps
with a pliers. 34 100 102 102 102 104 104 104 104 106 106 106 106 108 108

36 100 100 102 102 104 104 104 104 106 106 106 106 108 108

38 100 100 102 102 102 104 104 104 106 106 106 106 108 108

40 100 100 102 102 102 104 104 104 104 106 106 106 106 108

Standard main jet at delivery

These are the main jets for the carburetor Dell'orto PHF 30

5 26
 Basic Settings of the Carburetor Installation onto the Go-Kart
Carburetor Dell’orto PHF 30 DD1

Put the two hose clamps onto the

Main jet 106 carburetor rubber and push the
rubber onto the intake port.
Idle jet 55

Inner venturi BF1

Needle jet AB 260

Needle K29 Put the carburetor into the

carburetor rubber and tighten
Needle clip position 1 R.V.O. both hose clamps.

Accelerator pump: Check if the carburetor is

positioned horizontally.
Injection nozzle 38 Otherwise adjust carburetor
position accordingly.
Injection time 0.5 seconds =
Diaphragm stop position 3 ¼ turns open

Pull the crankcase ventilation

hose onto the ventilation tube and
push the tube into the
corresponding hole on the air
filter.

Install the air filter onto the

carburetor and tighten the hose
clamp.

Connect the crankcase ventilation

hose to the engine’s ventilation
tube.

Connect the gas line to the

carburetor.

25 6
 Installation onto the Go-Kart Electrical schematic
Step 2: Position the engine onto the go-kart.

Put the primary tube gasket into

the primary tube port.

Install the primary tube loose with 2

flange nuts M6 in order to be able
to position the primary tube.

Position the primary tube in that

way to leave a gap of 1mm.
Tighten both nuts.

Now install the engine onto the go-

kart.
The distance from the middle of the
rear axle to the middle of the
crankshaft is 230mm.

ca. 230mm

7 24
Assembling the Clutch Installation onto the Go-Kart

Lock the clutch with the special

tool “BATMAN” The distance between primary tube
and driver seat should result in
Install the clutch onto the min. 2cm.
crankshaft (do not forget the key).
Degrease the cone. In case that the primary tube is too
close to the seat or if you like a
different engine position compared
Tighten the clutch mount nut with to the seat you can adjust the
150 Nm. engine mount position accordingly.

Standard position middle

Slide the bent feeler gauge of
1.2mm between generator stator At delivery the engine mounts are
and the magneto. installed at the middle position.
Lock the clutch/crankshaft with the
„BATMAN“-tool.

Loosen the primary coil and push it

downwards. Tighten the generator Position left
stator bolts with 10Nm.
On the left position the engine is
moved 15mm closer to the seat.

Install the clutch drum and the Position right

transmission sprocket bearing.
Mount the „BATMAN“-tool. On the right position the engine is
moved 15mm off the seat.
Put on the transmission sprocket
bolt M6 with the thrust washer and
tighten the bolt with13 Nm. The bolts of the engine mount have to be tightened with Loctite 243 and 22Nm
torque.
Remove the „BATMAN“-tool.

23 8
 Installation onto the Go-Kart Changing the Clutch
Step 3: Install the battery box.

Install the control unit onto the two

silent blocks and tighten both
flange nuts M6. Remove all bolts on the back of
Lead the cables behind the control the starter sprocket.
unit.

Remove the battery and the rubber

floor.

Position the battery box in front of

the radiator.

The distance to the radiator should Now you can remove the clutch
result in 3-4cm in order to avoid from the starter sprocket and
problems when adjusting the chain. change the complete clutch or
just the clutch jaws.

Fix the battery box with the first

tube clamp onto the frame.

The other two tube clamps have to Mount the new clutch on the
be positioned according to the starter sprocket.
tube’s design. Based on this
position the corresponding holes Tighten all screws with 22Nm
have to be drilled. (3x M7 / 3x M8)

For doing this put the clamps onto The position of the clutch doesn’t
the frame and mark the hole matter.
position.
After having mounted all 3 tube
clamps reinstall the rubber floor
and the battery.

9 22
Dismantling the Clutch Installation onto the Go-Kart
Step 4: Wiring
Dismantle the generator stator

Loosen the transmission sprocket Connect the plus and the minus cable
bolt. on the battery with the provided slot
Remove the clutch drum and the nuts and bolts.
sprocket bearing.

Lock the clutch/crankshaft with the

„BATMAN“-tool.

Loosen the clutch mount nut.

Connect the engine wiring harness to
the control unit on the battery box.

Connect the engine ground cable

(black) to the engine.

Screw in the clutch puller into the

clutch mount by hand as far as Plug in the starter cable (red) on the
possible. free position on the starter relay.

Tighten the bolt till the clutch is

pulled away from the crankshaft.
Connect the engine wiring harness
with the generator.

21 10
Installation onto the Go-Kart Tips and Tricks
● How to find out the correct gear ratio
Choose the gear ratio in that way to run into the rev limiter for max. 1 second at
the end of the longest straight of the present race track.
Driving too long in the rpm limiter can damage the valve train.

● How to find out the correct carburetor adjustment

Please consider the enclosed main jet table. Ambient air pressure and
temperature have an influence on the choice of the carburetor nozzles.
Connect the engine wiring harness ● Scratches on the exhaust muffler
with the crank shaft trigger sensor. Conventional exhaust brackets from most of the go-kart manufacturers cause
scratches on the exhaust muffler due to the springs.
To avoid this we recommend to apply a protecting rubber.

● Lubricate chain and transmission sprocket bearing before every ride

Push the clutch drum

backwards and apply chain
spray between transmission
Connect the engine wiring harness
sprocket and thrust washer.
with the ignition coil.

● The clutch is not suited for standing race starts

Avoid starting at high speeds, otherwise the clutch is heated up heavily and
worn out badly.
The start/stop button has following On a race track with a high end speed the starting procedure with high
positions: revolutions increases the load on the clutch additionally!
1  Stop ● For a fast change of the gear ratio we recommend an additional clutch
drum with a pre-mounted transmission sprocket.
2  Ignition ON
(Position during driving)

3 2 1
3  Run starter motor ● All manuals and spare parts lists can be found on our homepage:

www.swissauto.com

11 20
 Recommended Accessories Installation onto the Go-Kart
These accessories are not included in the scope of supply. Step 5: Install the exhaust silencer

Torque absorber Install the exhaust silencer on a

commercially available exhaust
The torque absorber is a sprocket bracket (not included in the scope
mount on the rear axle, which of supply).
suits for all current rear
sprockets. Make sure that the silencer is in
line with the primary tube.
This torque absorber The silencer should be installed
considerably increases service horizontally. If necessary, loose
life of the chain. the nuts on the primary tube in
order to adjust the correct
position.

Connect the exhaust silencer and

Air box the primary tube with the 2
enclosed silencer springs.
The air box reduces noise
emissions considerably - without Retighten the nuts on the primary
any power losses. tube.

Step 6: Fuel hose

Protecting rubber

The protecting rubber avoids

scratches on the exhaust silencer Lead the gas line to the fuel
originating from the exhaust pump and connect it to the
bracket and the springs. free position on the fuel
pump.

Besides we recommend to take a charged spare battery with you to the racing
field.

19 12
 Installation onto the Go-Kart Special Tools
Step 7: Install the throttle cable. We recommend the following special tools:
● Clutch puller
● Clutch stop tool „BATMAN“
● Leaf metal ignition 1.2mm
Install the inner wire of the throttle ● Sprocket key Z13
cable on the carburetor and lead
the wire with the cable sleeve With these special tools the clutch and the transmission sprocket on the clutch
along the seat. drum can be dismantled and replaced.
Lead the throttle cable in that way These tools are not included in the scope of supply. Contact your dealer to get
to have a sufficient distance to these tools.
the exhaust manifold in order to
avoid damage due to heat
radiation from the exhaust clutch stop tool
manifold. „BATMAN“

The throttle cable should be

installed in that way to avoid
tension on the wire at idle
position. Otherwise the engine
will not idle properly.

At full throttle position the slide

must open completely.

The stop position on the pedal at

full throttle must be adjusted in
that way to avoid an overdraw of
the slide.

13 18
 Maintenance Start-up
● Apply full synthetic oil 0W30
We recommend lubricants from the company ’’Motorex’’.

Fill in 0.4l 0W30 motor oil from

‘’Motorex’’ into the engine.

● Oil refill capacity

After oil changing and service 0.4l.
After engine disassembling 0.6l.

● Air filter cleaning every 5h

A soiled air filter leads to considerable power losses. Clean the air filter with
gasoline. Fill in ca. 0.7l of water into the
radiator.
● Check valve clearance after the first 10h
Further checks of the valve clearance are not necessary.
Contact your dealer for carrying out this check.

● Valve springs changing after 20h + optical inspection

To avoid freezing of the cooling water (and therefore possible cracks on

● General check at your dealer’s shop every 40h cooler or casing) during wintertime, remove the water!

Use only unleaded fuel with min. 95 octane.

Modifications on the maintenance timetable are possible. The current version
of maintenance timetable you will find on our homepage: Fill the carburetor with gasoline by applying pressure onto the gas tank.
Pull the choke lever on the carburetor and press the start button.
www.swissauto.com Let the engine run for 10 seconds. Then switch it off and check the oil level.

The oil level should be now at or just slightly above the middle of the oil show
glass.
In case the oil level is too low fill it up.

These figures are based on experience and are no warranty agreement!

17 14
 Start-up Maintenance
The maintenance of the ’’swissauto 250 engine’’ is substantial for its service life.
If too much oil is present in the engine, the engine might eject the excessive oil by If maintenance is carried out incorrectly or insufficiently the service life might be
the crankcase ventilation hose into the air filter. reduced.
When the oil is warm the oil level should not pass the upper edge of the oil Therefore certain mechanic knowledge is required.
inspection glass. An air bubble should be still visible at the upper edge of the If there are points which are not clear contact your dealer.
show glass.
If this is not the case then remove the excessive oil until the reference level is ● battery recharges while driving
reached (see picture below). Charge your battery before every training day. The battery always discharge
itself slowly.

● Check oil level before every ride

Max. oil level warm If the oil level is too low you might risk to damage the engine.
If the oil level is too high oil is ejected and the air filter gets soiled.
Min. oil level warm
● When racing oil change is required every 1h or after every race, otherwise
every 3h

Oil drain plug Remove the oil drain plug and

clean the magnet on the bolt’s
end.
In case you observe excessive
wear contact your dealer.

Keep pushing the stop button to

avoid starting of the engine.
The cooling water system is self-venting. However, it is recommended to hold the Now push the start button in
hand on the radiator’s surface during warm up in order to check if the radiator is order to remove the remaining
heating up evenly. oil from the engine.
During the drive, the cooling water temperature should be between 50-90°C.
If the engine temperature is too low, cover the radiator in that way to achieve Every second oil change
above mentioned temperature range. remove the oil screen and clean
it.
Breaking-in the engine for 2 hours. Do not run the engine above 11’000 rpm
Remount the oil drain plug and
during this 2 hours.
tighten the bolt with 26Nm.

When installing the oil screen

pay attention to hit the port in
the oil chamber!
Tighten the bolt with 26Nm.

15 16