IAME Parilla LEOPARD Assembly Instructions & User Manual Download

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MAN048 ING

ISTRUZIONI DI MONTAGGIO

DI UTILIZZO

LEOPARD 125cc RL TaG K engine

ASSEMBLY INSTRUCTIONS

USER MANUAL

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Summary of Contents for Parilla LEOPARD

Page 1: ...MAN 048 ING ISTRUZIONI DI MONTAGGIO DI UTILIZZO LEOPARD 125cc RL TaG K engine ASSEMBLY INSTRUCTIONS USER MANUAL All manuals and user guides at all guides com...

Page 2: ...ions 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 RPM limitation 9 Inlet sil...

Page 3: ...witch key assembly and the wiring harness with a 5A fuse which connects the whole system The electronic box which controls the advance the rev limitation and the engine start stop logic integrates the...

Page 4: ...Never exceed the above limits no obligation of IAME exists in case the above limits are exceeded 1 CONTENTS OF THE PACKING Each Leopard engine is supplied with the accessories under shown EXHAUST SYST...

Page 5: ...CER TILLOTSON CARBURETOR ADDITIONAL ENGINE PLATE RADIATOR RADIATOR SUPPORT KIT WATER HOSE KIT COMPLETE PUMP GROUP NGK SPARK PLUG COMPLETE ELECTRIC ASSEMBLY EXHAUST SYSTEM CLUTCH COVER H T COIL STARTER...

Page 6: ...etter 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 ident...

Page 7: ...assembler to follow these instructions The final customer in this case can skip this section and can start reading from section 4 Whenever the engine or a component is disassembled it is necessary to...

Page 8: ...IXING BRACKET ON THE CLAMP N 2 SCREWS M6x12 AND PLACE THE CLAMPS ON THE REAR CROSS RAIL N 2 SCREWS M6x25 INSTALL THE PUMP ON THE BRACKET N 1 SCREW M8x45 WITH WASHER AND NUT SEE FIG 2 TIGHTEN BY HAND T...

Page 9: ...TS 5 INSERT THE 4 RUBBER DAMPENERS INTO THE FIXING HOLES ON THE RADIATOR SEE FIG 5 6 PLACE THE RADIATOR SUPPORT BRACKET BETWEEN THE RADIATOR FIXINGS BY TILTING ONE END AND INSERTING IT THROUGH THE RUB...

Page 10: ...SCREW M6x90 AND N 1 SCREW M6x85 WITH NUT INSTALL THE L SHAPE BRACKET ON THE LOWER RADIATOR CLAMP AVAILABLE IN DIFFERENT DIAMETERS 28 30 32mm 2 SCREWS M6x12 AND FIX IT TO THE TONGUE ON THE RADIATOR SU...

Page 11: ...ON THE RADIATOR OUTLET AND THE PUMP INLET TIGHTEN WITH STEEL CLAMPS ON BOTH SIDES CONNECT THE THIRD HOSE TO THE FITTINGS ON THE PUMP OUTLET AND THE ENGINE INLET TIGHTEN WITH STEEL CLAMPS ON BOTH SIDES...

Page 12: ...OVER 3 3 2 MAKE SURE THE EXHAUST GASKET IS IN SEAT AND INSTALL THE EXHAUST HEADER SEE FIG 1 3 3 3 INSTALL THE THREE WASHERS 3 3 4 INSTALL THE THREE NUTS TORQUE AT 9 11 Nm 80 100 in lb 12 POINT WRENCH...

Page 13: ...HT 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 10 4 ALLEN SCREWS M8 TORQUE AT 22 24 Nm 190 210 in...

Page 14: ...FIG 6 3 5 4 INSTALL THE INTAKE SUPPORT 2 SCREWS M5 X10 SEE FIG 7 ALLEN WRENCH 3 mm 3 5 5 INSTALL THE CARBURETOR SEE FIG 8 9 REMOVE THE TWO M6 NUTS FROM THE INLET MANIFOLD REMOVE THE PLASTIC PLUG FROM...

Page 15: ...E AT 6 10 Nm 50 90 in lb 3 6 INSTALL THE ENGINE ON THE CHASSIS 3 6 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 COMP...

Page 16: ...E 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...

Page 17: ...TYPE OF CHASSIS NOTE THE BOX AND CLAMPS ARE PROVIDED WITH VARIOUS HOLES WHICH ALLOW INSTALLATION ON ALL KIND OF CHASSIS 10mm BOX WRENCH 3 8 3 INSERT THE BATTERY IN THE BOX AND FASTEN WITH THE BATTERY...

Page 18: ...TION MAKE SURE THAT THE FIXING TONGUES ARE PROPERLY INSERTED TO GUARANTEE THE BEST POSSIBLE CONNECTION OF THE TERMINALS 3 8 6 CHECK THE ELECTRIC STARTER CABLE FIXING SEE FIG 22 AND COMPLETE THE FIXING...

Page 19: ...HE SECOND GROUND CABLE IN THE HARNESS CLOSE TO THE COIL CABLE TO THE H T COIL BY MEANS OF THE M6 NUT FIXING THE COIL SEE FIG 25 TORQUE AT 8 10 Nm 70 90 in lb ATTENTION THIS OPERATION IS EXTREMELY IMPO...

Page 20: ...TO THE 4 POLE TERMINAL IN THE WIRING HARNESS SEE FIG 30 ATTENTION MAKE SURE THAT THE FIXING TONGUES ARE PROPERLY INSERTED TO GUARANTEE THE BEST POSSIBLE CONNECTION OF THE TERMINALS 3 8 12 DRILL A 22mm...

Page 21: ...ELAY SEE FIG 33 NOTE CLEAN AND DEGREASE THE FAIRING FIXING SURFACE WHERE THE STRAP IS TO BE PLACED TO GUARANTEE THE BEST POSSIBLE STRAP ATTACHMENT 3 8 15 DRILL A FEW HOLES IN THE FAIRING TO ATTACH THE...

Page 22: ...REW THE SPARK CAP ON THE H T COIL SEE FIG 37 3 8 19 FIX THE CAP TO THE H T CABLE WITH A PLASTIC CLAMP SEE FIG 38 INSTALL THE SPARK PLUG TORQUE AT 20 26 Nm 175 230 in lb INSTALL THE CAP ON THE SPARK PL...

Page 23: ...5mm FLEXIBLE COMPLETELY CLOSED AND THE EXHAUST HEADER SEE FIG 40 AND FIT THE INSULATING SLEEVE ON THE FLEXIBLE SEE FIG 41 3 10 2 INSERT THE FLEXIBLE ON THE EXHAUST HEADER AND FIX WITH THE 3 SPRINGS SE...

Page 24: ...perience 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 start...

Page 25: ...tact with throttle lever Start the engine and warm it If RPM 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 id...

Page 26: ...he electric starter is immediately disengaged when turning the key to KEY position or when the electronic box detects an engine RPM higher than 1500 RPM C When the engine is running the key can be lef...

Page 27: ...ust header nuts as during the break in the nuts tend to become loose refer to the attached table 8 RPM LIMITATION The electronic box incorporates an RPM limiter which prevents the engine from exceedin...

Page 28: ...ng 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 sprock...

Page 29: ...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...

Page 30: ...3 Remove nut 1 nut M10 12 point wrench 17 mm 4 Remove the external washer the drum with roller bearing 5 Remove the special tool from the head and using the clutch wrench remove the 16x1 nut and the c...

Page 31: ...nternal 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 clu...

Page 32: ...these prescriptions are not followed the electrical system and the engine could be damaged beyond repair No obligation of IAME exists in this case 1 Please turn the key to STOP position every time the...

Page 33: ...ight cause malfunctions No obligation of IAME exists in this case 15 SPARK PLUG AND THERMAL DEGREE The engine is supplied with a standard NGK BR10EG spark plug which represents a good compromise betwe...

Page 34: ...nd 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 th...

Page 35: ...he 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...

Page 36: ...MAN 048 ING 34 SPROCKET RATIO TO ACHIEVE MAX 16500 RPM Sprocket ratio Engine Max RPM during tests All manuals and user guides at all guides com...

Page 37: ...E THE SCREW M6X30 ON THE STARTER SUPPORT see Fig 1 5mm ALLEN WRENCH T TYPE REMOVE THE STARTER SUPPORT 3 SCREWS M6X25 see Fig 2 5mm ALLEN WRENCH T TYPE UNSCREW N 3 SCREWS M6x35 see Fig 3 5mm ALLEN WREN...

Page 38: ...E STARTER REMOVE THE PLASTIC CLAMP AND UNSCREW THE SCREW M4 FIXING THE INPUT CABLE TO THE STARTER see Fig 5 SCREWDRIVER UNSCREW 3 SCREWS M5 C see Fig 6 SCREWDRIVER Fig 1 Fig 5 Fig 6 All manuals and us...

Page 39: ...Fig 8 ATTENTION WHEN EXTRACTING ROTOR THE BRUSHES MAY SPRING OUT FROM THEIR SEATS REPLACING THE BRUSH A UNSCREW THE 2 SCREWS M4 D RETAINING THE PLATE E see Fig 9 SCREWDRIVER REMOVE THE LITTLE RUBBER...

Page 40: ...E EXTERNALLY ON THE TIN PLATE TERMINAL REMOVE BRUSH see Fig 12 INSTALL NEW BRUSH TERMINAL INSIDE see Fig 13 PLACE LITTLE RUBBER CAP ON THE TERMINAL REINSTALL THE PLATE AND FIXE IT WITH THE 2 SCREWS M4...

Page 41: ...TOWARDS THE OUTER AND CLAMP IT WITH AN IRON WIRE BENT AS A HOOK REPEAT THE SAME PROCEDURE TO INSTALL THE BRUSH B see Fig 16 INSTALL THE STARTER ROTOR BETWEEN THE BRUSHES AND CHECK THAT THEY ARE ALWAYS...

Page 42: ...SCREW THE 3 SCREWS M5 see Fig 20 SCREWDRIVER CHECK THAT THE STARTER ROTOR ROTATES FREELY CONNECT THE INPUT WIRING TO THE STARTER WITH THE SCREW M4 see Fig 21 SCREWDRIVER ASSEMBLING THE STARTER PLACE...

Page 43: ...nd charge Cables and connectors Check status and connections Grounding of engine and electronic box Check status and connections Engine mount and clamps Check torques After use Battery Disconnect Chai...

Page 44: ...s and connection on fuel pipe Replace gaskets and membranes on carburetor Check reed petals Replace if necessary Engine starts but it stops after a few seconds when turning the key in RUN position Bad...

Page 45: ...t the battery and charge it periodically see Sect 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...

Page 46: ...MAN 048 ING 44 All manuals and user guides at all guides com...

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