IAME 125cc LEOPARD TaG Assembly Instructions And User'S Manual Download | Manualshive

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MAN-016 D

125cc LEOPARD TaG engine

ASSEMBLY INSTRUCTIONS

and

USER MANUAL

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Summary of Contents for 125cc LEOPARD TaG

Page 1: ...MAN 016 D 125cc LEOPARD TaG engine ASSEMBLY INSTRUCTIONS and USER MANUAL ...

Page 2: ...and connection of the power pack box 3 8 Electrical connections on the engine 3 9 Installation of the intake silencer 3 10 Install the exhaust 4 GASOLINE and OIL 5 Carburetor Adjustment guide 6 Starting and stopping the engine 7 Engine break in 8 Inlet silencer 9 Exhaust system 10 Centrifugal clutch 11 Instructions for the assembly disassembly of the clutch 12 Battery 13 Spark plug and thermal deg...

Page 3: ...s The main features of the ignition are During the start of the engine the power pack activates a booster which increases the spark energy to facilitate the starting of the engine The ignition system permits through the electronic unit the onboard battery recharging during the normal use of the engine The spark is generated also without a battery it is therefore possible in case of emergency to st...

Page 4: ...cation Fuel Oil mix Induction Reed valve Carburetor Membrane Tillotson Cooling water Ignition Digital 4 poles with internal rotor Battery charge With integral generator Electric start 12V 0 30 Kw Clutch Automatic dry centrifugal 2 OPERATIONAL LIMITS Max RPM 15000 RPM Min waterTemperature 45 c Max water Temperature 90 c ATTENTION Never exceed the above limits no obligation of IAME exists in case th...

Page 5: ...e Silencer 1 Intake Silencer Support 1 Accelerator Cable Bracket 1 ELECTRICAL Battery 12 V 1 Battery Support 1 Battery Strap 1 Battery Clamps 2 Power Pack Box with Harness 1 Plastic Fixing Clamps 8 NGK BR 10 EG Spark Plug 1 Spark Plug Cap 1 MISCELLANEOUS Additional Engine Plate 1 Additional starter support 1 Water proof cover 1 Clutch cover with H T coil 1 WATER COOLING Radiator 1 Radiator Support...

Page 6: ...ncludes a letter followed by 4 digits there can be exceptions in some special cases Other numbers stamped on the crankcase or other surfaces of the motor refer to various manufacturing processes and do not identify the motor NOTE In case of need for spares and when contacting the IAME Support Centers please always refer to the Motor Identification Number and to the motor model MAN 016 D 4 ...

Page 7: ...LL THE REAR AXLE AFTER HAVING INSERTED THE TWO BELTS SUGGESTION INSTALL OTHER TWO BELTS AS SPARES AND FIX THEM WITH TAPE TO THE AXLE 2 INSTALL THE WATER PUMP 1 SCREW M6 X 45 WITH WASHER AND SELF LOCKING NUT ON THE PUMP BRACKET ON THE REAR CROSS RAIL SEE FIG 1 IN CASE THERE IS NO BRACKET FOR THIS PURPOSE IT I S NECESSARY TO INSTALL THE PUMP ON REMOVABLE CLAMPS AVAILABLE IN DIFFERENT DIAMETERS 28 30...

Page 8: ...COMPONENTS 5 ASSEMBLE THE CONNECTING BRACKET ON THE RADIATOR SUPPORT BRACKET 6 INSTALL THE UPPER LEFT BRACKET ON THE CONNECTING BRACKET SEE FIG 5 7 INSERT THE RADIATOR BY FITTING IT ON THE SUPPORTS SEE FIG 6 Fig 4 Fig 5 RADIATOR SUPPORT BRACKET CONNECTING BRACKET UPPER LEFT BRACKET Fig 6 MAN 016 D 6 ...

Page 9: ...DIATOR SO THAT THE HOLE ON THE RADIATOR FIXING SUPPORT AND ONE OF THE UPPER HOLES OF THE BEARING SUPPORT BOX MATCH ONCE YOU FIND THE CORRECT POSITION FIX THE WHOLE 11 THE KIT INCLUDES TWO RUBBER HOSES CONNECT THE FIRST HOSE TO THE FITTING ON THE RADIATOR INLET AND THE FITTING ON THE ENGINE OUTLET TIGHTEN WITH STEEL CLAMPS SEE FIG 10 Fig 7 RADIATOR FIXING SUPPORT UPPER RIGHT BRACKET Fig 8 Fig 9 MAN...

Page 10: ...NDATIONS Unscrew the cap on the radiator and loosen the breather plug on the engine head Fill the radiator until the water comes out from the plug on the head there is no air in the system now and the radiator is completely filled Tighten the cap the system contains appr 1 lt of water It is advisable to put a small cup to recover water from the breather on the cap in case of boiling water After th...

Page 11: ...S SEATED AND INSTALL THE EXHAUST HEADER SEE FIG 1 3 2 3 INSTALL THE WASHERS SUGGESTION PUT THE ENGINE IN HORIZONTAL POSITION AND SET INTO POSITION THE WASHERS WITH A SCREWDRIVER 3 2 4 INSTALL THE THREE NUTS TORQUE AT 9 11 Nm 80 100 in lb 10 mm SOCKET WRENCH OR 10 mm OPEN WRENCH PREPARATION AND INSTALLATION OF THE MOTOR MOUNT NOTE ALL DIMENSIONS ARE IN MILLIMETERS 3 3 3 3 1 DRILL 4 HOLES DIAM 8 5mm...

Page 12: ...R MOUNT MAKE SURE TO USE M8 ALLEN SCREWS WITH A LENGHT SUCH AS TO ENGAGE IN THE CRANKCASE A THREADED PORTION LENGHT OF 16 19mm THE SCREW MUST PROTRUDE FROM THE PLATE FOR 16 19mm SEE FIG 3 AND DRAW PAG 9 4 ALLEN SCREWS M8 TORQUE AT 22 24 Nm 190 210 in lb 6 mm ALLEN WRENCH INSTALL THE CARBURETOR 3 4 3 4 1 INSTALL THE GAS CABLE CLAMP ON THE SUPPORT SEE FIG 4 12 POINT WRENCH 10mm Fig 2 Fig 3 Fig 4 MAN...

Page 13: ... SCREWS SEE FIG 6 3 4 4 INSTALL THE INTAKE SUPPORT 2 SCREWS M5 X10 SEE FIG 7 3 mm ALLEN WRENCH 3 4 5 INSTALL THE CARBURETOR SEE FIG 8 9 REMOVE THE TWO M6 NUTS FROM THE INLET MANIFOLD REMOVE THE PLASTIC PLUG FROM THE INLET MANIFOLD ATTENTION MAKE SURE THAT THE PRESSURE HOLE ON THE GASKET IS NOT PLUGGED 10MM OPEN WRENCH Fig 5 Fig 6 Fig 7 Fig 8 MAN 016 D 11 ...

Page 14: ...SHERS TORQUE AT 6 10 Nm 50 90 in lb 3 5 INSTALL THE ENGINE ON THE CHASSIS 3 5 1 POSITION THE ENGINE ON THE 2 OUTSIDE MAIN RAILS AND FIX THE MOTOR MOUNT WITH THE TWO CLAMPS SEE FIG 10 SUGGESTION NEVER TORQUE COMPLETELY THE CLAMPS UNTIL THE CHAIN IS INSTALLED AND PROPERLY ALIGNED 3 5 2 CHECK THE ALIGNMENT OF THE ENGINE SPROCKET AND THE AXLE SPROCKET WITH A STRAIGHT EDGE SEE FIG 11 3 5 3 INSTALL THE ...

Page 15: ... THE CRANKCASE SEE FIG 14 AND INSTALL THE CLUTCH COVER WITH H T COIL SEE FIG 15 TORQUE THE 3 SCREWS AT 8 10 Nm 70 90 in lb ATTENTION ALWAYS MAKE SURE THAT THE GROUND CABLE ALWAYS CONNECTS THE COIL WITH THE ENGINE AN INADEQUATE GROUNDING COULD DAMAGE THE IGNITION BEYOND REPAIR THE POSITION OF THE H T COIL HAS BEEN CHOSEN TO BE AS FAR AS POSSIBLE FROM THE EXHAUST AS THE EXCESSIVE HEAT COULD DAMAGE T...

Page 16: ...Y STRAP SEE FIG 16 3 7 2 POSITION THE SUPPORT CLAMPS ON THE OUTSIDE RAIL BRAKE SIDE AT THE HEIGHT OF THE SEAT NOTE DIFFERENT CLAMPS ARE AVAILABLE DEPENDING ON THE DIAMETER OF THE TUBE ON THE CHASSIS FIX THE CLAMPS BY HAND WITH 2 SCREWS M6 X 25 SEE FIG 17 3 7 3 POSITION THE BATTERY SUPPORT BOX ON THE CLAMPS MATCHING THE ATTACHMENT HOLES SEE FIG 18 FIX THE BOX WITH TWO SCREWS M6 X 10 MOVE THE BOX WI...

Page 17: ...TION NOT TO SHORT CIRCUIT THE BATTERY TERMINALS AS BATTERY COULD BE DAMAGED BEYOND REPAIR 3 7 6 GROUND THE POWER PACK ATTENTION AN INADEQUATE GROUNDING OF THE POWER PACK BOX COULD DAMAGE THE BOX BEYOND REPAIR MAKE SURE TO CAREFULLY FOLLOW THE UNDER SHOWN INSTRUCTIONS 3 7 6 1 REMOVE THE SCREW FROM THE SEAT SUPPORT LOCATED UNDERNEATH THE SEAT IN CASE THE POWER PACK BOX IS POSITIONED TOWARDS THE FRON...

Page 18: ...ENTRAL RAIL UNDERNEATH THE SEAT AND TIGHTEN WITH PLASTIC CLAMPS SEE FIG 24 ATTENTION NEVER LET THE HARNESS GET IN TOUCH WITH THE GROUND OR WITH ROTATING PARTS AS IT COULD BE DAMAGED BEYOND REPAIR 3 8 ELECTRICAL CONNECTIONS ON THE ENGINE 3 8 1 CONNECT THE TERMINALS 3 AND 4 WAYS ON THE HARNESS FROM THE POWER PACK BOX WITH THE TERMINALS ON THE CABLES FROM THE IGNITION SEE FIG 25 26 ATTENTION MAKE SUR...

Page 19: ...NSTALLED ON THE CABLE SEE FIG 27 3 8 3 FIX THE ELECTRIC STARTER AND THE CABLE SEE FIG 28 AND COMPLETE THE FIXING OF THE HARNESS SEE FIG 29 ATTENTION NEVER LET THE HARNESS GET IN TOUCH WITH THE GROUND OR WITH A ROTATING PART AS IT COULD BE DAMAGED BEYOND REPAIR Fig 26 Fig 29 Fig 28 Fig 27 MAN 016 D 17 ...

Page 20: ...N BEYOND REPAIR MAKE SURE TO CAREFULLY FOLLOW THE UNDER SHOWN INSTRUCTIONS 3 8 5 1 REMOVE THE SIDE BUMPER ON THE CHASSIS ENGINE SIDE IF NOT REMOVED YET 3 8 5 2 FILE THE PAINTING ON THE SLEEVE TO BARE METAL SEE FIG 31 ATTENTION THIS OPERATION IS EXTREMELY MPORTANT AS AN UNCERTAIN GROUNDING COULD DAMAGE THE IGNITION BEYOND REPAIR 3 8 5 3 INSTALL THE SIDE PLASTIC BODY AND CONNECT THE GROUND CABLE FRO...

Page 21: ...SPARK PLUG AND THE CAP OVER THE SPARK PLUG INSTALL THE SPARK PLUG INSTALL THE SPARK PLUG CAP MAKING SURE THAT THE SPRING IN THE CAP IS WELL INSERTED IN THE SPARK PLUG 3 9 INSTALL THE INTAKE SILENCER MAKE SURE THAT THE FILTER HAS THE INLET HOLES TOWARDS THE UPPER SIDE FIX THE FILTER ON THE CARB WITH A STEEL CLAMP AND THE FILTER TO THE CHASSIS SIDE RAILS WITH PLASTIC CLAMPS SEE FIG 35 36 Fig 33 Fig ...

Page 22: ... THE EXHAUST 3 10 1 INSTALL THE FLEXIBLE L 65mm FLEXIBLE COMPLETELY CLOSED AND THE EXHAUST HEADER SEE FIG 37 AND CONNECT THE EXHAUST 3 10 2 INSTALL THE FIBER STRIP AROUND THE FLEXIBLE AND FIX WITH THE 3 SPRINGS SEE FIG 38 Fig 37 Fig 38 THE ENGINE IS READY TO BE STARTED MAN 016 D 20 ...

Page 23: ... head Our experience dictates use of oils such as Shell Advance Racing M ELF HTX 909 ERG K KART 2T CORSE ERG K KART FORMULA Once the fuel tank is filled make sure that gasoline reaches the carburetor before starting the engine Never use the electric starter to suck the gasoline as this would discharge the battery SUGGESTION Disconnect the plastic tube on the carb and the vent tube on the tank and ...

Page 24: ... O L Adjust T O from closed to approximately 1 T O I Close by further 1 T O after contact with throttle lever Start the engine and warm it If R P M too high adjust I counterclockwise until clutch is disengaged Turn c c w until max R P M is reached Adjust further fractionally for rich idle Trigger accelerator If R P M decreases L Slowly adjust clockwise If R P M increases Continue to turn clockwise...

Page 25: ...ine gradually for about 5 minutes at half throttle making some laps at low speed gently closing and opening the carb throttle if a tachometer is installed never exceed 11 000 12 000 RPM Never keep the same RPM for a long time 3 Progressively increase the speed of the kart for 5 minutes at throttle opening Never keep the same RPM for a long time 4 Increase the speed for 5 minutes at max speed on th...

Page 26: ...rst welding on the first cone of the exhaust muffler see drawing To achieve this dimension the flexible supplied with the engine must be cut at a lenght of 65mm flexible completely closed Having fixed a sprocket ratio it could be necessary to improve the engine performance either at low or at high RPM This could be achieved by modifying the exhaust lenght In general by shortening the total exhaust...

Page 27: ... time the clutch has overheated presence of smoke or smell of burning To check the clutch you must remove the clutch cover and the clutch drum Replace the clutch whenever the thickness of the friction material see drawing is lower than 1 5mm on point A of the clutch or if the body diameter is lower than 82 5mm whenever the external friction material in the A portion of the clutch is very rough wea...

Page 28: ...1 OPERATIONS TOOLS Clutch disassembly 1 Remove the clutch cover 3 screws M6 Allen wrench 5mm T type 2 Remove the spark plug and replace with special tool to prevent crankshaft from turning Piston fitting P N 10271 3 Remove nut 1 nut M10 12 Point wrench 17 mm 4 Remove the external washer the drum with roller bearing the internal washer 5 Remove the special tool from the head and using the clutch wr...

Page 29: ...l part of engine 7 Install the piston fitting to prevent the shaft from turning and install the 10 mm nut Piston fitting P N 10271 17 mm socket Torque at 30 40 Nm 265 350 in lb 8 Install the clutch cover 3 screws M 6 Allen 5 mm Torque at 8 10 Nm 70 90 in lb 12 BATTERY The battery 12 V 7 2 Ah included in the supply is sealed and without maintenance In order to lengthen the battery life it is necess...

Page 30: ...epresents a good compromise between the needs of a good break in and the racing needs in normal conditions Use of different sparkplugs is possible and as a general information we are attaching a correspondence list among sparkplugs of other brands based on thermal degree which represents the capacity of the sparkplug to dissipate the internal heat The colour of the various parts of the sparkplug m...

Page 31: ...d by the manufacturer the wears and stress of the various components con rods roller cages bearings etc will be such as to drastically reduce the life of the engine itself It is therefore extremely important that the user respects the operating limits imposed by the manufacturer The operating limit for the Leopard engine is 15000 RPM ATTENTION Never exceed the above limits No obligation of IAME ex...

Page 32: ...rences between the engine ignition and the tachometer and or telemetry The following example should clarify the procedure for the optimization of the sprocket Assume to use the engine with Z 10 teeth engine sprocket and that during the preliminary track tests a Z 72 teeth axle sprocket has been used From table 1 with Z 10 as engine sprocket and Z 72 on the axle sprocket a ratio of 7 20 is found Ma...

Page 33: ...MAN 016 D 31 ...

Page 34: ...y Check status and charge Cables and connectors Check status and connections Grounding of engine and Power Pack Check status and connections Engine mount and clamps Check torques After use Battery Disconnect Chain Check status and oil chain Engine External cleaning Bendix assembly Remove cover see fig and clean internally Every 5 10 hours Exhaust muffler Remove muffler end clean Inlet silencer Ope...

Page 35: ...retor Check reed petals Replace if necessary Engine starts when the start bottom is pressed but it stops when bottom is released Bad cable connections Check stator connector 4 ways Bad connections on Power Pack internal cables Apply to Authorized Service Center Bad carburetor adjustment I screw Check carburetor adjustment see par 5 The starter cranks after having released the start button Battery ...

Page 36: ...s follows Disconnect the battery and charge it periodically see Par 12 Disconnect carburetor and clean it Seal with tape the engine inlet and exhaust The external of the engine must be cleaned Spray with protective oil the steel parts subject to oxidation Keep the engine in a dry ambient MAN 016 D 34 ...

Page 37: ...MAN 016 D 35 ...

Page 38: ...MAN 016 D 36 MAN 016 D 36 ...

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