Carter Service Bulletins

Posts: 14

I am going to post several service bulletins in this thread instead of making more threads. The actual bulletin will be in red.

MODEL 2861-XXXX (GTR250)

We have encountered some situations where the GTR250 seems to have low power. This service bulletin addressed the possible causes, along with the solution to each cause.

Condition: Buggy runs fine, but does not have the power that it should.

HERE ARE A FEW THINGS TO CHECK:

Possible Problem: Parking Brake too Tight.
First check the parking brake to see if it is too tight.
Solution – Adjust the parking brake. (See owner manual)

Possible Problem: Chain is too Tight
Check the chain adjustment to see if it is too tight.
Solution – Adjust the chain to ¼ free play. (See owners manual)

Possible Problem: Brake Rotors Dragging
Inspect the front brake rotors and make sure that they both turn freely with no drag.
Solution –Remove the brake caliper and place one 5/16 washer on each bolt in-between the brake caliper mount and strut.

Possible Problem: Throttle Cable
Throttle cable may have too much free-play (not getting full throttle)
Solution – adjust the cable so that it gets full throttle.(see service manual)

NOTE:- MAKE SURE THAT THE TIRE PRESSURE AND THE FRONT END ALIGNMENT IS CORRECT.

Posts: 14

NOTICE!!

MODEL: INTERCEPTOR GTR 250

THIS UNIT IS SHIPPED WITHOUT COOLANT

PLEASE ADD A 50/50 MIX OF ANTIFREEZE AND WATER TO THE COOLANT SYSTEM

PLEASE REFER TO YOUR SET UP INSTRUCTIONS ABOUT THE COOLANT SYSTEM.

IF YOUR GTR HAS ANY FLUID IN THE SYSTEM AT THE TIME OF DELIVERY TO YOU, PLEASE DRAIN ALL FLUID AND REFILL WITH THE ABOVE INSTRUCTIONS

Be sure to check especially if your in a cold climate.

Posts: 14

BACK-FIRE REDUCTION ON THE GTR

Parts included in kit: ( Parts number: 8256-3000 )
Large plug
Small plug
110 main jet

With an 8mm and 10mm wrench remove heat shield from cargo rack.

Remove secondary air cleaner by pulling off both the hose on the head of the engine and intake manifold.
Be sure not to remove the hose running to the fuel pump.

With the provided plugs, cap off both ports the hoses were removed from. Be sure to clamp both plugs with existing clamps.
The new plugs have a smaller outside diameter than the removed hoses. With a pair of pliers squeeze the clamps decreasing their inside diameter to fit the plugs.

Remove the slide and needle from the carburetor.

With a pair of needle nose pliers move the needle clip down one position to the 4th slot.

Remove carburetor from unit.
Take the bowl off the bottom of the carburetor.
Remove existing main jet and replace with 110 main jet.

Reassemble carburetor, install on unit, and reinstall heat shield.

Not all units are backfiring, but if yours is you can order the kit or have your dealer do it.

Posts: 14

GTR STEERING IMPROVEMENT

On some of our GTR units the steering is not sufficient. The steering system turns more to the right than to the left. In order to fix this situation, we must shorten the steering stop tubing by ½” and set the steering system correctly.

Shorten the steering stop.
a. Remove the passenger side rubber boot, ball joint end, and steering stop tubing.
b. Cut off ½” on one end of the steering stop tubing and reassemble.

Rubber boot Ball joint end Steering Stop Tubing

Setting the steering system.
b. The steering wheel must be set upright when the rack and pinion is centered.
c. The rack and pinion is centered when it has the same amount of travel to both the right and left side.
d. In order to check this:
a. Center the steering wheel.

b. Turn the wheel to the left and to the right.

c. The steering wheel must lock in both directions the same position as shown.
d. If the steering wheel does not lock the same as the picture above you must remove the steering wheel from the steering U-joint, rotate the wheel the appropriate direction and then reinsert the steering wheel into the steering U-joint.
e. Now you must set the tires to point straight and parallel with each other.

f. Now you must check to see if each tire turns the same
a. Do this by turning the tires to the left and to the right and checking how close each inside tire comes to the frame.

Trying to copy pics as well but not having much luck....I'll get it figured out yet...

Posts: 14

Technical Notice for GTR 250
(Wiring for the Temperature Control Box)

On some of our GTR 250’s we have noticed that there is a 25-33mA draw being placed on the battery when the key is in the “OFF” position. This is because the temperature control box is wired directly to the battery and should only be getting power when the key is in the “ON” position.

How to correct this problem:
There is a Red/White wire going into the plug of the temperature control box.

Peel the electrical tape around this wire 3-4 inches back and cut the Red/White wire.
Be sure to tape back over the wires.
You will have 2 Black wires going into your fuse box.

Peel the electrical tape around these wires 3-4 inches and connect the Red/White wire to either of the 2 Black wires.

NOTE: We have experienced some electrical issues with batteries not charging, overheated electrical components, and engine temperature light staying on. This situation occurs because there are two wires being crossed leading to the temperature control box. The incorrect wiring is listed below, with the correct wiring listed afterward:

Green wire to Green wire
Black wire to Red/White wire
Brown wire to Brown/White wire
Green/Yellow wire to White/Blue wire

The correct wiring pattern should be:
Green wire to Green wire
Black wire to Red/White wire
Brown wire to White/Blue wire
Green/Yellow wire to Brown/White wire

I realise this may be difficult to do without the pics also, but at least you know what need to be done....

Posts: 4286

thats good info, I have it printed out from from carter as well.

Posts: 200

The backfire solution takes out the AICV unit.
That what i did on mine the first week i had it.
Exhaust was getting red hot (literally)
Don't need that environmental stuff running extra air into pipe.

I also noticed it was running very lean... temp light kept lighting up. So changed the jet to 110 and later 112. Back firing gone!

Jackster

Posts: 228

Mine is backfiring after going WOT and then decelerating. Other thsn that it runs fine. Plug was slightly white when I pulled it out. Not sure how many turns that screw on the carb is in or out.

Posts: 200

Sounds like your running a bit lean.
I know mine did when it was stock.
I bet your temp light comes on quite quickly too.
After about 15-20 min.

Air screw on stock carb is 3 half turns out.
Changing this setting will not eliminate the backfiring.
I tried every increment up to 4 whole turns out.
No effect on the back firing.

Only after changing the main jet to a bigger size and
getting rid of the AICV the problem was solved.

I talked to the Carter importer for Europe about this.
(I talk to the guy quite regularly as he is located only 15 miles from where I live) They started changing the main jet to 112 and taking off the AICV on all affected Carter GTR's they deliver to the dealers. Note that not all SYM 250 engines are affected.
But clearly, as mine was, yours is too.

If you don't want to take off the AICV just yet (there could be some warranty issues) You could clamp off the vacuum line to it and the plug the little white filter on its intake.

Jackster

Posts: 228

I do not see how clamping it off to see what happens would void the warranty when Carter's fix basically eliminates the whole thing. I will give it a shot.

What is the stock main jet? I see Carter's fix replaces it with a 110. I am at or below sea level I think....