NATIONAL HOMOLOGATION FORM KARTING ENGINE

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1 NATIONAL HOMOLOGATION FORM KARTING ENGINE Manufacturer BRIGGS & STRATTON Make BRIGGS & STRATTON Model Validity of the homologation 6 years Number of pages 25 This Homologation Form reproduces descriptions, illustrations and dimensions of the engine at the time that Karting Australia conducted the homologation. PHOTO OF DRIVE SIDE OF ENGINE PHOTO OF OPPOSITE SIDE OF ENGINE Signature and Stamp of Karting Australia Les Allen National Technical Inspector 20 December 2017 Copyright 2017 Karting Australia. All rights reserved. 1

2 PHOTO OF DRIVE SIDE OF THE COMPLETE ENGINE Copyright 2017 Karting Australia. All rights reserved. 2

3 PHOTO OF OPPOSITE DRIVE SIDE OF THE COMPLETE ENGINE Copyright 2017 Karting Australia. All rights reserved. 3

4 PHOTO OF THE REAR OF THE COMPLETE ENGINE Copyright 2017 Karting Australia. All rights reserved. 4

5 PHOTO OF THE FRONT OF THE COMPLETE ENGINE CLOSEUP OF SEAL There are two custom, Homeland Security Tier III rated seals installed at the factory. Tampering of the seals is not permitted. Should the seals be tampered with or broken, the engine is no longer eligible for competition. No deviation from the manufacturer s engine specification is permitted. All components must remain OEM. The engine serial number must be visible at all times and must comply with the Australian homologation. Copyright 2017 Karting Australia. All rights reserved. 5

6 PHOTO OF THE COMPLETE ENGINE TAKEN FROM ABOVE Copyright 2017 Karting Australia. All rights reserved. 6

7 PHOTO OF THE COMPLETE ENGINE TAKEN FROM BELOW There are two custom, Homeland Security Tier III rated seals installed at the factory. Tampering of the seals is not permitted. Should the seals be tampered with or broken, the engine is no longer eligible for competition. CLOSEUP OF SEAL Copyright 2017 Karting Australia. All rights reserved. 7

8 TECHNICAL INFORMATION A CHARACTERISTICS The number of decimal places must be 2 or comply with the relevant tolerance. Tolerances & remarks Cylinder Volume of cylinder 204cm³ Original bore mm -- Theoritical maximum bore mm -- Original Stroke 55.88mm -- Number of transfer ducts, cylinder/sump N/A / -- Number of exhaust ports / ducts 1 -- Volume of the combustion chamber 3.711cm³ minimum Volume of the combustion chamber in the cylinder head cm³ minimum Crankshaft Number of bearings 2 -- Diameter of bearings 47MM 0.1mm Minimum weight of crankshaft 1673g minimum All parts represented on page 17 photo Balance shaft Minimum weight of balance shaft N/A g minimum Percentage of balancing N/A % minimum Connecting rod Connecting rod centreline mm 0.2mm Diameter of big end 27.99mm 0.05mm Diameter of small end 15.89mm 0.05mm Min. weight of the connecting rod g minimum Copyright 2017 Karting Australia. All rights reserved. 8

9 Piston Number of piston rings 3 Min. weight of the bare piston g minimum Gudgeon pin Diameter 16.55mm 0.05mm Length 48.41mm 0.15mm Minimum weight 43.39g Minimum Clutch Minimum weight N/A minimum Of all the parts represented on the page 21 technical drawing B OPENING ANGLES Of the inlet (main transfer ports) N/A 2 Of the inlet (secondary transfer ports, for 5 transfer ducts engine) N/A 2 Of the exhaust N/A 2 Of the boosters N/A 2 C MATERIAL Cylinder head Cylinder Cylinder wall Sump Crankshaft Connecting rod Piston Single Cast Aluminium Single Cast Aluminium CAST IRON SLEEVED ALUMINIUM CAST IRON Squeeze Cast T-7 Aluminium ALUMINIUM No deviation from the manufacturer s engine specification is permitted. All components must remain OEM. The engine serial number must be visible at all times and must comply with the Australian Homologation. ALL THE ENGINE PARTS MUST BE ORIGINAL BY BRIGGS & STRATTON. Neither engines nor accessories can be modified. By this we mean any shape, content or function changes which may differ from what previously conceived. Furthermore this includes any addition and /or removal of material and /or parts from the engine set-up package unless provided by this regulation. No ceramic component coatings. Copyright 2017 Karting Australia. All rights reserved. 9

10 D PHOTOS, DRAWINGS & GRAPHS D.1 CYLINDER UNIT EXPLODED ILLUSTRATION OF THE CYLINDER, CYLINDER HEAD AND EXHAUST MANIFOLD UNIT Without screws or gaskets. The aim of thexploded drawings is to identify the principles, the functioning and the whole mechanical unit Copyright 2017 Karting Australia. All rights reserved. 10

11 ... Section D.1 EXPLODED ILLUSTRATION OF THE CYLINDER DEVELOPMENT Copyright 2017 Karting Australia. All rights reserved. 11

12 DRAWING OF THE CYLINDER BASE without dimensions PHOTO OF THE CYLINDER BASE Copyright 2017 Karting Australia. All rights reserved. 12

13 ... Section D.1 ILLUSTRATION OF THE CYLINDER HEAD AND OF THE COMBUSTION CHAMBER without dimensions Copyright 2017 Karting Australia. All rights reserved. 13

14 PHOTO OF THE CYLINDER HEAD PHOTO OF THE COMBUSTION CHAMBER IN THE CYLINDER HEAD PHOTO OF THE CYLINDER FROM ABOVE PHOTO OF THE CYLINDER FROM RH SIDE Copyright 2017 Karting Australia. All rights reserved. 14

15 D.2 CONROD, CRANKCASE, CRANKSHAFT & PISTON EXPLODED ILLUSTRATION OF THE PISTON, CRANKSHAFT, CONNECTING ROD AND CRANKCASES UNIT (exploded crankshaft) There are two custom, Homeland Security Tier III rated seals installed at the factory. Tampering of the seals is not permitted. Should the seals be tampered with or broken, the engine is no longer eligible for competition. Without screws or gaskets. The aim of the exploded drawings is to identify the principles, the functioning and the whole mechanical unit Copyright 2017 Karting Australia. All rights reserved. 15

16 ...Section D.2 DRAWING OF THE CRANKSHAFT & CONROD PHOTO OF THE CONROD Copyright 2017 Karting Australia. All rights reserved. 16

17 DRAWING OF THE PISTON (MAIN DIMENSIONS incl. tolerances) Copyright 2017 Karting Australia. All rights reserved. 17

18 Section D.5 EXHAUST SYSTEM EXHAUST MANIFOLD, HEADER AND SILENCER Copyright 2017 Karting Australia. All rights reserved. 18

19 Section D.5 D.8 ELECTRICAL SYSTEM IGNITION SYSTEM Copyright 2017 Karting Australia. All rights reserved. 19

20 ... Section D.5 D.8 CARBURETTOR CARBURETTOR SYSTEM Copyright 2017 Karting Australia. All rights reserved. 20

21 ... Section D.5 D.8 CLUTCH CLUTCH Copyright 2017 Karting Australia. All rights reserved. 21

22 TECHNICAL SPECIFICATIONS 1. General Rules a. Unless in the Rules and these Homologation Documents and Technical Specifications, it says that you can do something then you cannot. b. Only the original equipment Briggs and Stratton 206 # is permitted for use. c. The engine and all its components must remain as originally supplied and unaltered. d. No aftermarket parts can be used unless specified herein. e. All parts are subject to comparison with the homologated part. This includes specified and mandated aftermarket parts. Example: RLV exhaust and Silencer. f. The Briggs and Stratton 206 must have a sealed and serialised block. 2. FOR THE AVOIDANCE OF DOUBT - Things That Are NOT Permitted a. Tampering with the factory installed engine seals (2). b. Addition or subtraction of material in any form or matter. The only exception to this is Valve maintenance. Valve seats must remain with the factory specification of 30 and 45 angles only. Valve seats of additional angles and/or angles not comparable to the homologated components of 30 and 45 are not permitted. Grinding of valve stem or excessive material removal is prohibited. c. Blueprinting. d. Modification to or the machining of any part/s to bring them to the minimum/maximum specification., e. Machining or alteration of any kind to the engine or replacement parts unless specifically stated herein. f. Deburring, machining, honing, grinding, polishing, sanding, media blasting, etc. g. Sandblasting or glass-beading any interior engine surfaces. h. No device may be used that will impede, or appear to impede, airflow to the engine cooling system. 3. Engine Sealing a. There are two custom, Homeland Security Tier III rated seals installed at the factory. b. Both (2) B&S engine seals must be present with both the fastener and seal in as shipped from the factory location and condition. c. Tampering with or breaking the seals is not permitted. Should the seals be tampered with or be broken, the engine will no longer be eligible for competition. Tampering includes interfering with the fasteners and/or damage to or breakage of the wire/seal itself (for example: delamination of the hologram). o Take proper care of your seals to ensure their integrity. It is recommended that you wrap your seals (using a plastic bag, etc.) to prevent exposure to harsh solvents such as carb cleaner, etc Engine Ignition Switch a. The B&S ignition switch and wires must remain in the original location. b. It is not permitted to alter the OEM wiring. 5. Engine Air Filter a. The only air filter permitted to be used is the Briggs & Stratton Green Air Filter Part # as homologated. No modification to the filter is permitted. b. A protective shield may be attached for wet-weather or dusty competition. c. It is not permitted for the protective shield to create any ram-air effect. 6. Engine Oil a. No oil additives are permitted. b. Only Briggs & Stratton 4T Synthetic Racing Oil is permitted for use with the engine. 7. Fuel Pump a. The B&S fuel pump - part number , is the only fuel pump permitted for use in competition. b. This fuel pump is identified by the Briggs & Stratton diamond logo on the pump face. 8. Carburetor & Intake Manifold a. The B&S stock carburetor part # is the only carburetor permitted for use. Walbro, Briggs diamond logo and/or # etched in the body are additional visual indicators. Copyright 2017 Karting Australia. All rights reserved. 22

23 b. No alterations allowed unless stated below. c. All parts will be compared to the homologated OEM part to determine eligibility. d. It is permitted to adjust the float height by means of bending the small tab on the float arm. e. Slide must remain B&S OEM unaltered. f. Idle pilot jet must remain OEM and be clearly identified with its original etched or stamped 32 as supplied with the engine. g. Main jet must also remain OEM and be clearly identified with its original etching or stamped 95 as supplied with the engine. h. B&S OEM unaltered aluminum needle is required part number marked #BGB. i. Throttle cable cap on the top of the carburetor must be properly installed and secured in the fully tight position. j. Choke must be OEM and unaltered. The lever may be fastened open with a spring, rubber band, wire, etc. k. Main Jet #95 ONLY 9. Cylinder Head a. The ONLY head casting for the B&S 206 herein is the RT-1 (cast into the head just off the head gasket surface towards the rear of the engine, PTO side). The overall head minimum thickness is 61.7mm b. Cylinder head must be as cast. Factory machining marks left on the head gasket surface are a tech item. c. Hard carbon may be scraped from head before measuring. d. Depth of shallow area of combustion chamber must be 7.6mm minimum. a. This measurement to be taken with a depth gage on both the combustion side and spark plug side of cylinder head. e. Depth of the combustion chamber is 8.66 minimum. f. Inspect retainers for alterations that would increase valve spring pressure 0.14mm to 0.19mm maximum flange thickness. Both intake and exhaust must have OEM B&S valve keepers. g. Unaltered B&S part # (exhaust) and # (intake) can be checked for appearance, weight, and dimensions. No machining, polishing, easing, or alterations of any kind allowed. Valve surface must remain as factory, with one single 45 face. No other additional angles allowed on any part of the valve. h. Valve Guides: Replacement of valve guides with B&S part # only is allowed. Maximum depth from the head gasket surface to the intake valve guide is 31.87mm 10. Head Gasket a. Unaltered B&S part # is the only head gasket permitted to be used. b. Minimum thickness allowed is.1.25mm. Measurement must be performed using a micrometer. Readings are taken from inside the cylinder hole of the gasket closest to the combustion chamber. Four measurements must be taken with 3 meeting the minimum thickness of 1.25mm. 11. Ports a. No de-burring, machining, honing, grinding, polishing, sanding, media blasting, etc is permitted. b. The transition from intake bowl to port must have factory defined machining burr at this junction. No addition or subtraction of material in any form or matter. No alterations of any kind may be made to the intake or exhaust ports. c. Intake Port: Maximum diameter measurement 23.32mm d. Exhaust Port AS CAST. Exhaust Outlet e. Valve Seats. Intake and exhaust: Must remain factory specification with one 30 and one 45 angle only. Valve seats of additional angles and/or angles not comparable to the factory stock are not permitted. f. Valve maintenance permitted. Valve seats must remain with the factory specification of 30 and 45 angles only. Valve seats of additional angles and/or excessive material removed when compared to the factory stock is prohibited. Maximum inside intake valve seat diameter 24.69mm Intake port pocket bowl (area just below valve seat) = no go Maximum inside exhaust valve seat diameter 21.59mm 12. Valves a. Intake valve Minimum Weight of Valve 27.8 grams Diameter of valve stem 6.25mmto 6.27mm Diameter of valve head 26.80mm to Maximum inside diameter of valve seat 24.68mm Copyright 2017 Karting Australia. All rights reserved. 23

24 Valve length Minimum 85.48mm Minimum height from angle of valve face to top of the valve 1.45mm b. Exhaust valve Minimum Weight of Valve 27.2 grams Diameter of valve stem 6.25mmto.6.27mm Diameter of valve head 23.75mmto 24.00mm Maximum inside diameter of valve seat 21.59mm Valve length Minimum 85.48mm Minimum height from angle of valve face to top of the valve 1.52mm 13. Valve Springs a. Valve Springs are single coil stock, unaltered B&S part #26826 as homologated. They must be identical in appearance to factory part and have 4.00 to 4.75 coils in stack. b. Spring Wire Diameter: 2.62mm to 2.72mm c. Valve spring length: 23.88mm maximum d. Inside diameter: 15.62mm to 16.13mm 14. Rocker Arms, Rocker Ball and Rocker Arm Studs a. Rocker arm must be OEM part # (METRIC) as homologated and must not be altered in any way. b. Rocker studs must be OEM, part # Metric (M8x1.00 thread) as homologated and must not be altered in any way. c. Rocker arm OEM part # (Metric) must be used with rocker stud OEM part # (Metric). d. Rocker Ball must be OEM. Diameter 14.99mm minimum to 15.49mm maximum. e. Rocker arm mounting positions must not be altered in any way. No helicoiling of mounting holes is permitted. It is not permitted to bend the studs. f. Rocker arm stud plate must be bolted to the head with one OEM gasket as homologated no alterations are permitted. Maximum thickness of gasket is 1.52mm. Rocker plate to head fastener holes must remain in accordance with the homologation 7.34mm maximum. g. Minimum overall Rocker arm length 71.63mm. 15. Push Rods a. Push rods must be OEM part # as homologated and must not be altered in any way. Push rod length mm minimum to mm maximum. Push rod diameter 4.7mm minimum to 4.83mm maximum. 16. Engine Block a. Engine block must be unaltered as cast B&S factory machined condition. b. There must be no addition or subtractions of metal or any substance to the inside or outside of the cylinder block. c. Deck gasket surface finish is not a tech item. d. Maximum permitted Piston pop is 0.127mm. Piston pop-up to be checked with flat bar in center of piston parallel to piston pin and then again checked 90 degrees to piston pin. e. Angle milling, or peak decking is not permitted. 17. Valve Lift a. Maximum valve lift is checked from the top of the valve spring retainer. Valves must be adjusted to zero clearance. b. Camshaft check is taken at the valve spring retainers. With the lash set at zero, the movement of the valve spring retainers may not exceed the following: o Intake and exhaust: 6.48mm maximum. 18. Flywheel a. The flywheel must be OEM part # as homologated and must not be altered in any way. No machining, glass beading, sand blasting, painting or coating of flywheel is permitted. b. The minimum weight of the flywheel, fins and attachment bolts is 1.843kg. c. The flywheel fan must be OEM part# as homologated and must not be altered in any way. Copyright 2017 Karting Australia. All rights reserved. 24

25 It is not permitted to use a flywheel fan with broken fins or fins that have been removed or damaged. d. OEM unaltered flywheel key with the B&S logo must be used. Width of the key allowed is 4.64mm 4.76 No offset keyways are permitted. 19. Ignition System a. The ignition must be B&S ignition OEM part # as homologated and must not be altered in any way. Only the GREEN ignition module is permitted to be used. Maximum RPM: 6,150. b. The Coil and its position, other than air gap may not be altered in any way. Coil mounting bolts must be OEM and cannot be altered in any way to advance or retard timing. Attachment bolts and/or bolt holes may not be altered. c. Only the OEM factory Spark Plug part number # Champion RC12YC is permitted for use. The Spark Plug must have the Champion and Briggs & Stratton logo as well as the RC12YC identification on the insulator. Sealing washer must be in place as from factory. d. Magneto air gap is non-tech (recommended clearance of 0.406mm) e. Ignition timing: Maximum of 30 BTDC f. Spark plug connector: Only the OEM part # is permitted for use. 20. Clutch a. Only the Flame Clutch OEM part # as homologated is permitted for use. No alteration to the clutch is permitted save for the: springs, drive sprocket size and clutch key (all non-tech items) b. Clutch coolers are not permitted for use. 21. Starter a. Recoil Starter - OEM part # as homologated is the only recoil starter permitted for use and must not be altered in any way. b. The Recoil Starter maybe rotated. 22. Exhaust Header a. Header must be RLV Model 5507 as homologated is the only header permitted for use and must not be altered in any way. b. Header length: mm +/- 6.35mm along the short side. c. A maximum of one (1) gasket and/or silicone are permitted to be used to seal the header to head. d. Studs or bolts are permitted to fasten header to head. Bolts or nuts must be safety wired. e. Helicoiling of the exhaust is permitted. f. The use of the header support brace is mandatory. The addition of a mechanical support bracket (no welding involved) is permitted, provided that there are no alterations to the shape or dimensions of the exhaust configuration. g. Any modification for or use of an O2, EGT, CO2 sensor is prohibited. 23. Exhaust Silencer a. Silencer IKD 99 RLV with round baffle holes only as homologated is the only silencer permitted for use and must not be altered in any way. No machining, glass beading, sand blasting, painting or coating of flywheel is permitted b. Safety wiring of the silencer to header is mandatory. c. All 4 baffles must remain unaltered and the hole size can be verified using a no-go pin of d. Exhaust gases must only exit through the muffler baffles. e. The Muffler must be mounted on the header in a way that does not allow exhaust gases to leak at the joint. 24. Exhaust Protection a. The header must be completely wrapped (360 ) with an: insulation sleeve supplied by IKD; or non-asbestos, insulation wrap material. b. The insulation wrap material or sleeve must be securely affixed to the header starting approximately 75mm from the exhaust flange extending to the point where the OEM supplied RVL support meets the header. Copyright 2017 Karting Australia. All rights reserved. 25

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