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MAN048 ING

1

INDEX

GENERAL DESCRIPTION OF THE ENGINE
CHARACTERISTICS OF THE "LEOPARD" ENGINE – OPERATIONAL LIMITS

1 Contents of the packing

2 Motor identification Number

3 Preparation and installation of the engine on the chassis

3.1 Installation sketch of the engine on the chassis

3.2  Install the water cooling system
3.3   Exhaust header assembly
3.4  Preparation and installation of the motormount
3.5   Install the carburetor
3.6   Install the engine on the chassis
3.7   Install the clutch cover with H.T. coil
3.8  Electrical connections
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 breakin

8 RPM limitation

9 Inlet silencer

10 Exhaust system

11 Centrifugal clutch

12 Instructions for the assembly/disassembly of the clutch

13 Battery

14 Warnings on the electrical system

15 Spark plug and thermal degree

16 Choice of the best sprocket ratio

17 Replacement of the starter brushes

18 Scheduled maintenance

19 Troubleshooting

20 Engine and accessories preservation

21 Fastener Torque Table

Wiring diagram

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Содержание Parilla Leopard TaG Series

Страница 1: ...MAN 048 ING ISTRUZIONI DI MONTAGGIO DI UTILIZZO LEOPARD 125cc RL TaG K engine ASSEMBLY INSTRUCTIONS USER MANUAL...

Страница 2: ...3 8 Electrical connections 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...

Страница 3: ...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 controls the advance the rev limitation and the engine start st...

Страница 4: ...erature 65 c ATTENTION 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 u...

Страница 5: ...TH SUPPORT INTAKE SILENCER TILLOTSON CARBURETOR ADDITIONAL ENGINE PLATE RADIATOR RADIATOR SUPPORT KIT WATER HOSE KIT COMPLETE PUMP GROUP NGK SPARK PLUG COMPLETE ELECTRIC ASSEMBLY EXHAUST SYSTEM CLUTCH...

Страница 6: ...r 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 pro...

Страница 7: ...s it is at care of the 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 disassemb...

Страница 8: ...2mm 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...

Страница 9: ...THE FOLLOWING COMPONENTS 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 INSER...

Страница 10: ...T 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 TO...

Страница 11: ...D HOSE TO THE FITTINGS 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 STE...

Страница 12: ...NUTS AND THE EXHAUST COVER 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...

Страница 13: ...LLEN 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 10 4 ALLEN SCREWS M8 TORQUE...

Страница 14: ...AND THE TWO SCREWS SEE 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 REMOV...

Страница 15: ...6 AND TWO WASHERS TORQUE 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 SUGGE...

Страница 16: ...M6 X 30 ON 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 TH...

Страница 17: ...E BOLT DEPENDING ON THE 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...

Страница 18: ...ARNESS SEE FIG 21 ATTENTION 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...

Страница 19: ...YELET TERMINAL 7mm OF THE 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 OPER...

Страница 20: ...NECT THE STARTER RELAY 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 TERMIN...

Страница 21: ...C BOX AND THE STARTER RELAY 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 TH...

Страница 22: ...THE TERMINALS 3 8 18 SCREW 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...

Страница 23: ...NSTALL THE FLEXIBLE L 65mm 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 FI...

Страница 24: ...ton and the 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...

Страница 25: ...further 1 T O after contact 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 f...

Страница 26: ...n to 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 1500 RPM C When the engine is run...

Страница 27: ...the torque of the exhaust 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 t...

Страница 28: ...r up to the first 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 close...

Страница 29: ...000 RPM Every 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...

Страница 30: ...ston 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 5 Remove the special tool from the head and using the clutch wrench remove...

Страница 31: ...er with bevel towards internal 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...

Страница 32: ...he engine ATTENTION If 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...

Страница 33: ...ginal electric system might 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...

Страница 34: ...anufacturer 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 th...

Страница 35: ...interferences 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...

Страница 36: ...MAN 048 ING 34 SPROCKET RATIO TO ACHIEVE MAX 16500 RPM Sprocket ratio Engine Max RPM during tests...

Страница 37: ...MBLE THE STARTER UNLOOSE 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 s...

Страница 38: ...048 ING 36 2 OPENING THE 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 F...

Страница 39: ...R FROM STARTER HEAD see 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 RE...

Страница 40: ...SPRINGS MAKING PRESSURE 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...

Страница 41: ...H 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 16 INSTALL THE STARTER ROTOR BETWEEN THE BRUSHES AND CHE...

Страница 42: ...F THEIR SEAT see Fig 19 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 ASSEMB...

Страница 43: ...Battery Check status and 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...

Страница 44: ...tion system Check status 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...

Страница 45: ...ed as follows Disconnect 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 Sp...

Страница 46: ...MAN 048 ING 44...

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