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MAN-88 – UK

 

GENERAL DESCRIPTION OF ENGINE  

 

This engine is for propaedeutic series and for very young drivers and has been specifically 
designed  and  developed  for  powering  of  kart,  either  for  racing  purposes  and  hobby,  but 
always on closed tracks. 
During  the  design  phase  has  been  inspired  to  the  technical  solutions  already  adopted  for 
high-performance  engines  kart,  to  its  simplicity  of  installation  and  use,  related  to  a 

parsimonious maintenance, in order to ensure the maximum durability and reliability of the 
components, subject to compliance with the operational limits. 
 
The engine is single-cylinder and uses the principle OTTO two stroke. 
 

The cylinder and the crankcase are made in aluminium alloy. 
The pressed-in lineris made of centrifuged cast iron, fully machined from a solid to ensure 
the best stability and homogeneity of sliding. 
The head is separated from cylinder and is secured to the cylinder with through studs. 
The crankshaft is built and supported by ball bearings. It’s made of alloy steel, hardened and 

tempered,  as  well  as  the  connecting  rod  (which  also  undergoes  a  surface  treatment  of 
copper plating), which rotates on roller-bearings on both sides. 
 
The ignition system is of analogical type with discharge capacity, is powered by a flywheel 
and  a  coil  whose  functions  are  to  generate  the  spark  energy  required  for  a  proper 
management of goodwill, provide the references phase by a pick-up integrated. 
The  plant  comprises  a  rotor-stator,  a  high  voltage  coil,  which  allow  the  control  of  the 
advance. 
The engine is equipped with a pull starter.  
The  engine  is  also  equipped  with  a  centrifugal  dry  clutch  with  low  maintenance  with 
incorporated sprocket. 
The carburettor type is a diaphragm (series Tillotson HS) includes an integrated fuel pump 
and filter with the air manifold also. 
 
The exhaust system, including in the supply, is already tuned and optimized to ensure the 
best possible performance. 
 
 
 
 
 

 
 

 
 

 
 
 

 

ENGINE CHARACTERISTICS

 

 

Summary of Contents for M1 60cc

Page 1: ...ASSEMBLY INSTRUCTIONS AND USER MANUAL MAN 088 M1 60cc...

Page 2: ...hassis 3 6 Install the clutch cover 3 7 Electrical connection 4 Gasoline and Oil 5 Tillotson HS 323A Carburettor Adjustament 6 Starting and Stopping the engine 7 Engine Breaking In 8 Inlet Silencer 9...

Page 3: ...m cylinder and is secured to the cylinder with through studs The crankshaft is built and supported by ball bearings It s made of alloy steel hardened and tempered as well as the connecting rod which a...

Page 4: ...he above limits are exceeded 1 CONTENTS OF PACKING Each engine is supplied with the accessories under shown EXHAUST GROUP Quantity Exhaust Muffler Gasket 2 Exhaust Manifold with restrictor 11 5mm 1 Ex...

Page 5: ...FICATION NUMBER EXHAUST GROUP SPARK PLUG NGK CLUTCH COVER CYLINDER CYLINDER HEAD THERMAL PROTECTION SAFETY COVER INTAKE SILENCER FIXING CLAMP INTAKE GROUP TILLOTSON HS 323A CARBURETTOR COIL SWITCH CAB...

Page 6: ...cludes a letter followed by 4 digits Other numbers stamped on the crankcase or other surfaces refer to various manufacturing processes and do not identify the engine NOTE In case of need for spare par...

Page 7: ...his section and can start reading from section 4 Whenever the engine or a component is disassembled it is necessary to always follow the under shown instructions for proper reassembly 3 1 INSTALLATION...

Page 8: ...ROTECT THE INTERNAL PARTS REMOVE THE EXHAUST COVER GASKET INSTALL THE SCREWS AND THE WASHER ON THE SAFETY COVER OF THE MUFFLER n 2 M6x95 n 1 M6x12 n 3 WASHER 24 6 6 n 3 ELASTIC WASHER FOR M6 POSITION...

Page 9: ...HE MUFFLER WITH ITS SAFETY COVER ON THE ENGINE AND TIGHTEN BUT NOT DEFINITELY ALL SCREW OF FIXING WHEN THE POSITION OF THE ALL COMPONENTS IS CORRECT TIGHTEN DEFINITELY ALL SCREWS N 3 SCREWS WITH 5 mm...

Page 10: ...IONS ARE IN MILLIMETERS INSTALL THE MOTOR MOUNT MAKE SURE TO USE M8 ALLEN SCREWS WITH A LENGTH SUCH AS TO ENGAGE IN THE CRANKCASE A THREADED PORTION LENGHT OF 16 19MM THE SCREW MUST PROTRUDE FROM THE...

Page 11: ...HTEN DEFINITELY THE SCREWS WITH THE 5MM ALLEN WRENCH TORQUE AT 6 10 Nm 50 90 in lb Pre assembling N 2 SCREWS M6x95 INTO THE INLET MANIFOLD AND TAKE A POSITION OF THE CARBURETTOR AS IN PICTURE BETWEEN...

Page 12: ...WITH THE FLATHEAD OR PHILLIPS SCREWDRIVER CONNECT BY APPROPRIATE PIPE THE INTAKE PRESSURE MANIFOLD ON THE CARBURETTOR AND THE INTAKE PRESSURE MANIFOLD ON THE CRANKCASE CONNECT BY APPROPRIATE PIPE THE...

Page 13: ...ELY THE CLAMPS UNTIL THE CHAIN IS INSTALLED AND PROPERLY ALIGNED CHECK THE ALIGNMENT OF THE ENGINE SPROCKET AND THE AXLE SPROCKET WITH A STRAIGHT EDGE INSTALL THE CHAIN PITCH 7 775mm MOVE THE ENGINE O...

Page 14: ...ICAL CONNECTION CONNECT THE COIL CABLE SMALL ONE TO THE TERMINAL ON THE COIL CONNECT THE COIL CABLE AT THE TERMINAL ON THE ON OFF SWITCH INSTALL THE SPARK PLUG ON THE CYLINDER HEAD AND INSTALL THE SPA...

Page 15: ...o check and clean at least every 5 10 hours the piston and the cylinder head Our experience dictates use of oils such as WLADOIL K 2T KART RACING OIL SHELL ADVANCE RACING M ELF HTX 909 Once the fuel t...

Page 16: ...e necessary to reset the carburettor to optimize the performance of the engine ATTENTION Never lean too much as lean mixture will overheat engine and cause seizure The adjustment of the High screw is...

Page 17: ...g the switch on the OFF position 7 ENGINE BREAKING IN The breaking in of the engine must be performed following a few fundamental rules Adjust the carburetion Start with an adjustment on the rich side...

Page 18: ...s still avoid useless accelerations which can overheat and deteriorate the clutch early Lubrificate the chain before each test immediately after each session and check the engine sprocket Replace if n...

Page 19: ...y for blocked the crankshaft Clutch wrench CH 24 Special tool S 1436 2 3 Remove drum nut N 1 nut M10 12 Point wrench 17 mm 4 Remove the external washer the drum with roller cage the O Ring and the int...

Page 20: ...internal washer and the O ring ATTENTION install washer with chamfer towards internal part of engine Clean the roller cage and grease it before installing on the crankshaft 1 Install the clutch drum...

Page 21: ...mixtures can generate the same final look which can be also achieved with a hot or cold spark plug See table an excessively warm spark plug shows the symptoms listed aside ATTENTION Use a warmer spark...

Page 22: ...ket ratio in order to achieve the best possible performance without abusing the engine follow the under shown recommendations The engines are supplied with a 10 or 11 teeth sprocket pitch 7 775mm Tabl...

Page 23: ...cket and Z 72 on the axle sprocket a ratio of 7 20 is found Make a few laps on the track and let us assume that you read 11 000 max engine RPM From the table 2 to achieve a max RPM of 12 500 RPM opera...

Page 24: ...and connections Engine mount and clamps Check torques After use Chain Check status and oil chain Engine External cleaning Engine used in rain conditions Clean carefully the engine interior and the clu...

Page 25: ...he prescribed clearance between cylinder and new piston is 0 07mm The effective piston diameter has to be verified at 15mm from the base perpendicularly to the piston pin Size of the liner to be match...

Page 26: ...t can be made every 300lt MAIN BEARING The replacement can be made every 300lt CONROD The replacement can be made every 600lt Anyway it must be replaced whenever the big end hole ovalization exceeds 0...

Page 27: ...k carburettor adjustment see Sect 5 Drop in engine performance Bad compression Check piston Bad carburettor adjustment Check carburettor adjustment see Sect 5 Insufficient fuel flow Check fuel flow li...

Page 28: ...x0 8 2 CARBURETTOR MANIFOLD SCREWS Allen 4 5 6 45 50 M6x1 2 INLET MANIFOLD SCREWS Allen 5 6 8 50 70 FIXING CLAMP 1 FIXING CLAMP SCREW Screwdriver 6 8 50 70 M4x0 7 2 COIL SCREWS Allen 3 5 6 45 50 M5x0...

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