IAME X30 125cc RL - TaG Скачать руководство пользователя

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- 2 - MAN-043E ENG

I N D E X

PAGE

Section 1 DESCRIPTION OF THE “IAME X30 125cc RL - TaG” ENGINE

1.1.

Main features

1.2.

Characteristics of the Engine / Operational limits

1.3.

Contents of packing

1.4.

Accessories

1.5.

Motor identification number

Section 2 PREPARATION & INSTALLATION OF THE ENGINE ON THE CHASSIS 06

2.1.

Installation sketch of the engine on the chassis

2.2.

Install the water-cooling system

2.3.

Exhaust header assembly

2.4.

Preparation and installation of the motor-mount

2.5.

Install the carburettor

2.6.

Install the engine on the chassis

2.7.

Install the clutch cover with H.T. coil

2.8.

Mounting of the electric plant and connectors

2.9.

Install the intake silencer

2.10.

Install the exhaust

Section 3 ENGINE USE 21

3.1.

Charging of the oil in the gear box

3.2.

Gasoline and oil

3.3.

Carburettor adjustment guide

3.4.

Starting and stopping the engine

3.5.

Engine running-in

3.6.

RPM limitation

3.7.

Inlet silencer

3.8.

Recommendations on the exhaust system

3.9.

Recommendations on the battery

3.10.

Warnings on the electrical system

3.11.

Spark plug and thermal degree

3.12.

Choice of the sprocket ratio

Section 4 ENGINE BASIC MAINTENANCE 32

4.1.

Centrifugal Clutch

4.2.

Instructions for the clutch disassembly\ assembly

4.3.

Gear timing schematic

4.4.

Replacement of the starter brushes

4.5.

Troubleshooting 41

4.6.

Engine and accessories preservation 42

4.7.

Scheduled maintenance

4.8.

Table for wear evaluation on bearing / halfcrank shafts 44

4.9.

General Prescriptions 45

5.0. Con-rod big and small end bearing tolerances 46
5.1.

Torque Value

5.2.

Cross pattern locking order on crankcase 48

5.3.

Overhaul tool list 49

5.4.

Fixing tool on vice benk vice 50

5.5.

Oil seal assembly tool (dwg. S 725 / 1) 51

5.6.

Wiring diagram

Содержание X30 125cc RL - TaG

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 33: ...31 MAN 043E ENG...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

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

Страница 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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