TEKA

Briggs and Stratton ‘Animal’

Fitting the AKA homologated TEKA “Powermac” exhaust system

Intro

The new AKA homologated exhaust system has been introduced to comply with noise level restrictions specified in the AKA karting manual. The exhaust system kit comes complete with an exhaust mounting bracket and muffler cradle to allow a quick change over for all B&S teams.

Performance under race conditions was found to be equivalent to the old exhaust system.

Manufactured by Powermac Products Pty Ltd, a reputable kart exhaust manufacturer, the TIG welded baffle type exhaust system is manufactured using tooling jigs to achieve consistent finish dimensions.

Note:

The exhaust mounting bracket and muffler cradle has not been homologated, modification or changing of these items is allowed.

Exhaust System kit contents

1 x Muffler body complete with engine pipe

1 x Header pipe

1 x Exhaust mounting bracket

1 x Muffler cradle complete with 2 x 10 mm height adjusting nuts

2 x Long springs for muffler body

2 x Short springs for muffler pipe to header pipe

1 x ½ inch UNF x ¾ inch long low profile hex head bolt

Additional Materials(not supplied in kit)

1 x Exhaust Gasket, Briggs and Stratton P/No. 691893

2 x 6mm diameter (dia) x 1mm pitch x 15 mm long or if UNC thread ¼ inch UNC

x 5/8 inch long bolt or socket head cap screw

Thread locking compound such as “Loctite”

Anti-seize compound (recommended)

1 x 10mm spring washer

Multi-strand cable and suitable cable clamps.

1Preparation

1.1Remove existing exhaust system

1.2If the exhaust gasket is in good condition it may be reused. Preferably fit a new gasket.

1.3Place a clean piece of cloth in the exhaust port to prevent any debris entering the port. Clean exhaust port flange.

1.4Inspect the two threaded 6mm dia x 1.0 mm pitch exhaust mount holes for damage.

1.5Carefully remove cloth. Use a vacuum cleaner if debris has entered the port.

1.6Check the two holes in the cylinder head either side of the bottom rocker cover screw are threaded and if threaded determine thread type.These threaded holes will secure the rear of the new exhaust mount.

1.7Remove chain guard for easy access

2Fitting

2.1Place the exhaust gasket on the reduced pipe diameter end of the header pipe and push all the way up against the flange and align mounting holes.

2.3Insert the header pipe into exhaust port and secure with 2 x 6mm bolts.

2.4Position the exhaust mount so that the front slotted hole and two rear mounting holes are aligned with the threaded mounting holes. Screw the two rear mounting screws in to hold the exhaust mount.

2.5Apply a bead of thread locking compound to thread of ½ inch UNF bolt. Insert bolt through slotted ½ inch clearance hole of exhaust mount and screw bolt in about 5mm into ½ inch UNF threaded hole of the crankcase cover.

2.6Tighten 2 x 6 mm bolts. Recommend lock wire bolts.

2.7Tighten ½ inch UNF bolt (19mm or ¾ inch socket).

2.8Thread 1 x 10mm adjusting nut onto the muffler cradle threaded spigot.

2.9Insert muffler cradle threaded spigot into 10 mm clearance hole.

2.10Thread 1 x 10mm nut onto the bottom of the threaded spigot.

Note: Recommend adding a spring washer under the lower nut.

2.11Align the muffler engine over pipe over the header pipe and the muffler body over the exhaust cradle and drop into position over the slip joint.

Note: Recommend lightly smearing inside of the engine pipe that covers the header pipe with anti-seize.

2.12Adjust the height of muffler cradle so that the engine pipe is seating in as close to a neutral position with minimal load on the engine pipe.

2.13Tighten upper and lower nuts.

2.14Fit 2 x (short) springs between engine pipe lugs and header pipe lugs.

2.15Fit 2 x (long) springs over muffler body and attach to lugs on cradle.

2.16Insert restraint cable through the fixing lug provided on rear of muffler body and secure at a fixing point on the kart chassis with suitable cable clamps in accordance AKA rule 25.09 paragraph 5.

2.17Replace the chain guard, check clearance, trim as required.