IAME X30 125cc RL - TaG Assembly Instructions & User Manual Download

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- 1 - MAN-043E ENG

MAN-043E - ENG

ASSEMBLY INSTRUCTIONS

USER MANUAL

125cc RL - TaG

Summary of Contents for X30 125cc RL - TaG

Page 1: ...1 MAN 043E ENG MAN 043E ENG ASSEMBLY INSTRUCTIONS USER MANUAL 125cc RL TaG...

Page 2: ...21 3 2 Gasoline and oil 21 3 3 Carburettor adjustment guide 22 3 4 Starting and stopping the engine 23 3 5 Engine running in 24 3 6 RPM limitation 24 3 7 Inlet silencer 24 3 8 Recommendations on the...

Page 3: ...es a digital electronic unit the stator rotor the starter relay the H T coil a switch key assembly and the wiring harness with a 5A fuse which connects the whole system The electronic box which contro...

Page 4: ...123 67 cc 125cc max 54 00 mm 54 28 mm 54 00 mm Fuel oil mix 4 5 22 1 Reed valve in the crankcase Membrane TRYTON HOBBY 27 C 26mm Water forced Digital with integrated rev limiter With integral generat...

Page 5: ...26 1 Intake silencer 1 ELECTRICAL PLANT Battery support plate 1 Battery support 1 Battery stripe 1 Battery fixing clamps dampeners 2 Mounting screws washers kit 1 Electronic box 1 Starter relay 1 H T...

Page 6: ...SSORIES EXHAUST SYSTEM CLUTCH COVER H T COIL INLET SILENCER CARBURETTOR TRYTON HOBBY RADIATOR RADIATOR SUPPORT KIT WATER HOSES KIT WATER PUMP ASSEMBLY THERMOSTAT SPARK PLUG KIT BRUSHES KIT ELECTRIC PL...

Page 7: ...mber normally includes 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...

Page 8: ...re of the assembler to follow these instructions The final customer in this case can skip this section and can start reading from section 3 Whenever the engine or a component is disassembled it is nec...

Page 9: ...ASSEMBLE THE PUMP FIXING 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...

Page 10: ...LE THE FOLLOWING COMPONENTS 5 INSERT THE 4 RUBBER DAMPENERS INTO THE FIXING HOLES ON THE RADIATOR SEE FIG 5 PLACE THE RADIATOR SUPPORT BRACKET BETWEEN THE RADIATOR FIXINGS BY TILTING ONE END AND INSER...

Page 11: ...CKET RADIATOR CAP SIDE N 1 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...

Page 12: ...MPS ON BOTH SIDES SEE FIG 11 10 TO INSTALL THE THERMOSTAT REGULATING THE WATER TEMPERATURE CUT THE HOSE CONNECTING THE FITTING ON THE RADIATOR INLET AND THE FITTING ON THE ENGINE OUTLET INSTALL THE TH...

Page 13: ...NUTS AND THE EXHAUST COVER 2 3 2 MAKE SURE THE EXHAUST GASKET IS IN SEAT AND INSTALL THE EXHAUST HEADER SEE FIG 2 2 3 3 INSTALL THE TWO WASHERS 8mm 2 3 4 INSTALL THE TWO 2 NUTS M8 TORQUE AT 18 22 Nm 1...

Page 14: ...2 5 INSTALL THE CARBURETOR 2 5 1 REMOVE THE PLASTIC PLUG FROM THE INLET MANIFOLD SEE FIG 4 WARNING MAKE SURE THAT THE PRESSURE HOLE ON THE GASKET IS NOT PLUGGED 2 5 2 INSTALL THE CARBURETOR TWO 2 NUT...

Page 15: ...NTIL THE CHAIN IS INSTALLED AND PROPERLY ALIGNED 2 6 2 CHECK THE ALIGNMENT OF THE ENGINE SPROCKET AND THE AXLE SPROCKET WITH A STRAIGHT EDGE SEE FIG 7 2 6 3 INSTALL THE CHAIN PITCH 7 775 SEE FIG 8 2 6...

Page 16: ...THAN 6 7 mm WIDEN THE CHAIN OPENING WITH A FILE TO CHECK THIS WE SUGGEST TO INSTALL THE SPROCKET WITH THE HIGHEST AVAILABLE TOOTH NUMBER 2 7 2 CONNECT THE COIL COPPER CABLE ON THE HOLE ON THE CRANKCA...

Page 17: ...ALL CHASSIS PLACE THE SUPPORT PLATE ON THE SUPPORT AND FIX THROUGH THE N 3 SCREWS M5x10 AND CONCERNED WASHERS AND NUTS TORQUE AT 6 8 Nm 50 70 in lb WRENCH 4mm PLACE THE ELECTRONIC BOX ON THE PLATE AN...

Page 18: ...DICATED HOUSING Fig 19 SLIDE THE BATTERY FIXING STRIPE IN THE DEDICATED SLOTS Fig 20 PLACE THE BATTERY IN THE DEDICATED SLOT Fig 21 PLACE THE CABLES AT DESIRED CONVENIENCE IN A PRACTICAL AND SAFE WAY...

Page 19: ...NTEE THE CORRECT CONTACT OF THE TWO ENDS AND A SAFE TIGHTENING VERIFY THE PRESENCE OF THE PLASTIC CLAMP ON THE STARTER MOTOR AND THAT IT FIXES THE CABLE ON THE BODY OF THE STARTER ENGINE FIG 25 WARNIN...

Page 20: ...OLE END OF THE SECOND GROUND CABLE TO THE H T COIL THROUGH THE M6 NUT OF THE H T COIL FIG 28 TORQUE AT 8 10 Nm 70 90 in lb WARNING THIS OPERATION IS FUNDAMENTAL AS AN IMPROPER GROUNDING COULD IRREPARA...

Page 21: ...TO GUARANTEE THE CORRECT CONTACT OF THE TWO ENDS AND A SAFE TIGHTENING SCREW THE SPARK PLUG CAP ON THE H T COIL CABLE FIG 34 Fig 34 FIX THE SPARK PLUG CAP ON THE H T COIL CABLE WITH A PLASTIC CLAMP F...

Page 22: ...0 1 INSTALL THE FLEXIBLE L 65mm FLEXIBLE COMPLETELY CLOSED AND THE EXHAUST HEADER SEE FIG 37 AND FIT THE INSULATING SLEEVE ON THE FLEXIBLE SEE FIG 38 2 10 2 INSERT THE FLEXIBLE ON THE EXHAUST HEADER A...

Page 23: ...ngine to discharge the oil through the oil level plug 3 2 GASOLINE AND OIL Use leaded or unleaded Premium gasoline 95 ROM mixed with oil at 4 5 22 1 Use oils containing castor oil which guarantees an...

Page 24: ...from closed to approximately 1 T O 1 turn I Close by further 1 T O after contact with throttle lever Start the engine and warm it If RPM too high adjust counterclockwise until clutch is disengaged If...

Page 25: ...start the engine the electric starter is immediately disengaged when turning the key to KEY position or when the electronic box detects an engine RPM higher than 1 500 RPM C When the engine is runnin...

Page 26: ...to become loose refer to the attached table 3 6 RPM LIMITATION The electronic box incorporates an RPM limiter which prevents the engine from exceeding 14 000 15 500 or 16 000 RPM depending on the engi...

Page 27: ...performance is achieved with a total exhaust lenght of L 445 450 mm Where L is measured from the flange on the exhaust header up to the first welding on the first cone of the exhaust muffler see drawi...

Page 28: ...efore and the pole positive terminal after Always disconnect the battery in opposite order Recharge the battery at least once every 6 months Never let the battery tension dropping under 8V as whenever...

Page 29: ...tly in contact with the laminations pack on the H T coil 8 Never use H T coils different than the original coil on the engine Use of different coil may cause damages to the electronic box 9 The digita...

Page 30: ...an generate the same final look which can also be achieved with a hot or cold spark plug See table An excessive warm spark plug shows the symptoms listed aside WARNING Always use a warmer than standar...

Page 31: ...dations The engines are supplied with a 11 teeth sproket pitch 7 775 mm but 10 and 12 teeth sprockets are available as accessories Table 1 shows the various ratios between the sprocket on the axle and...

Page 32: ...a ratio of 7 70 is found Make a few laps on the track and record the maximum engine rpm achieved Let us assume that you detect 13 600 RPM From the Table 2a to achieve a max RPM of 14 000 RPM operatin...

Page 33: ...31 MAN 043E ENG...

Page 34: ...age irreparably the sprocket Check the clutch every 5 hours of use When metallic noises are heard inside the clutch If the kart dragging speed exceeds 6000 RPM Every time the clutch has overheated pre...

Page 35: ...Starter wheel locking tool P N S884 3 Remove nut 1 nut M10 12 point wrench 17 mm 4 Remove the external washer the drum complete with roller cage the internal washer 5 Remove the special tool from the...

Page 36: ...locking tool S 884 12 point wrench 30 mm torque at 100 110 Nm 885 970 in lb 4 Install the internal washer ATTENTION install washer with bevel towards internal part of the engine Clean the roller cage...

Page 37: ...MBLE THE STARTER UNSCREW N 2 SCREWS M6x35 see Fig 1 5mm ALLEN WRENCH T TYPE REMOVE STARTER see Fig 2 NOTE ON THE ENGINES MANUFACTURED AFTER SEPTEMBER 05 THE STARTER CAN BE REMOVED WITHOUT TAKING AWAY...

Page 38: ...NG 2 OPENING THE STARTER REMOVE THE PLASTIC CLAMP AND UNSCREW THE SCREW M4 FIXING THE INPUT CABLE TO THE STARTER see Fig 3 PHILLIPS SCREWDRIVER UNSCREW 3 SCREWS M5 C see Fig 4 PHILLIPS SCREWDRIVER Fig...

Page 39: ...ROM STARTER HEAD see Fig 6 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 7 PHILLIPS SCREWDRI...

Page 40: ...INGS MAKING PRESSURE EXTERNALLY ON THE TIN PLATE TERMINAL REMOVE BRUSH see Fig 10 INSTALL NEW BRUSH TERMINAL INSIDE see Fig 11 PLACE LITTLE RUBBER CAP ON THE TERMINAL REINSTALL THE PLATE AND FIXE IT W...

Page 41: ...BRUSH IN PLACE BY PRESSING 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 14 INSTALL THE STARTER ROTOR BETWEEN THE BRUSHES AN...

Page 42: ...Fig 18 PHILLIPS SCREWDRIVER CHECK THAT THE STARTER ROTOR ROTATES FREELY CONNECT THE INPUT WIRING TO THE STARTER WITH THE SCREW M4 see Fig 19 PHILLIPS SCREWDRIVER SECURE THE WIRE TO THE STARTER BY MEA...

Page 43: ...gaskets and membranes on carburettor Check reed petals Replace if necessary Engine starts but it stops after a few seconds when turning the key in RUN position Bad cable connections Check stator conn...

Page 44: ...ape 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 In the event of a long unope...

Page 45: ...Coil and electronic box Check status and restore the connections Engine mounts and clamps Check torques Battery support and clamps Check torques After use Battery Disconnect Chain Lubrication chain En...

Page 46: ...96 BALANCE SHAFT EXTERNAL BEARING SEAT MICROMETER 0 25 1 100 MIN 24 96 BALANCE SHAFT INTERNAL BEARING SEAT MICROMETER 0 25 1 100 MIN 14 95 CRANKSHAFT BEARINGS 1 100 BORE GAUGE WITH CHECK RING 30 MAX...

Page 47: ...on top of piston with a green or red dot or with letter V green or R red If the size on piston top is marked with a green dot or letter V add 0 01mm to size marked on the piston to match the liner siz...

Page 48: ...46 MAN 043E ENG 5 0 MATCHING PLAYS CONROD LOWER AND UPPER END...

Page 49: ...17 20 26 175 230 M6x1 3 Bendix support screw Allen 5 6 8 50 70 M6x1 2 Starter fixing screws Allen 5 8 10 70 90 M6x1 3 Clutch cover fixing screws Allen 5 8 10 70 90 M10x1 1 Clutch holding Nut Hex 17 3...

Page 50: ...48 MAN 043E ENG 5 2 CROSS PATTERN LOCKING ORDER ON CRANKCASE...

Page 51: ...OL BEARING ASSEMBLY TOOL INTERNAL BALANCE SHAFT BEARING ASSY DISASSY TOOL OIL SEAL ASSEMBLY TOOL without crankshaft OIL SEAL ASSEMBLY TOOL with installed crankshaft GEAR COVER OIL SEAL ASSEMBLY TOOL 1...

Page 52: ...50 MAN 043E ENG 5 4 FIXING TOOL ON VICE BENCH...

Page 53: ...51 MAN 043E ENG 5 5 BEARING OIL SEAL ASSEMBLY TOOL DISEGNO S725 1...

Page 54: ...52 MAN 043E ENG 1 ELECTRONIC BOX 2 RELAY 3 STARTER KEY 4 FUSE HOLDER 5 BATTERY 6 IGNITION 7 STARTER MOTOR 8 H T COIL 5 6 WIRING DIAGRAM...

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