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PRD Fireball 125cc-TaG Installation & User Manual

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Summary of Contents for PRD Fireball 125cc-TaG

  • Page 1 C o u r t e s y o f...

  • Page 2: Table Of Contents

    INDE X Page GENERAL ENGINE DESCRIPTION GENER AL ENGINE SPECIFICATIONS Complete Engine Package Engine Serial Numbers Installation Instructions 3.1 Photo of Engine Mounted on Frame 3.2 Installing the Water Cooling System 3.3 Installing the Header 3.4 Engine Mount Preparation 3.5 Installing the Carburetor 3.6 Installing the Chain 3.7 Installing the Clutch Cover, Gear Plate Guard &...

  • Page 3: General Engine Description

    GENER AL ENGINE DESCR IPT ION The PRD 125cc Fireball engine is a “TaG” (Touch and Go) style engine. This engine is a hobby engine and designed only for closed course racing on tracks built for this specific purpose. The engine is a single cylinder 2-stroke.

  • Page 4: Gener Al Engine Specifications

    GENER AL ENGINE DESCR IPT ION (continued) Battery 12 volt with a battery box to hold the battery. Exhaust Pipe & Supplied with a connector tube to create the preferred tuned length. Header Complete Kit Includes all switches, radiator, radiator mount, radiator hoses, water pump and more.

  • Page 5: 1- Complete Engine Package

    Section 1 COMPLETE ENGINE PACKAGE Engine Box Engine Header Reed manifold & reeds (installed) Dry clutch (installed) Starter (installed) Bendix (installed) Accessory Box Cooling System Radiator Radiator hoses Radiator mount Water pump Water pump pulley (2) Water pump belts Electrical System Battery Battery box Wiring harness...
  • Page 6 ACCESSORIES Exhaust Battery and Box Tillotson Carburetor System Radiator and Mounting Easy Start Ignition System Clutch Cover w/ Coil Complete Water Pump Intake Silencer Spark Plug Radiator Hose Kit...

  • Page 7: 2- Engine Serial Numbers

    Section 2 ENGINE SERIAL NUMBERS Each engine is stamped with a unique serial number. The serial number is displayed to the right of the intake manifold at the base of the engine. This serial number will always start with US and a four digit number “US 2700”...

  • Page 8: 3- Installation Instructions

    Section 3 INSTALLATION INSTRUCTIONS Note: If your engine is already assembled and mounted on the chassis move to section 4. Section 3.1 General wiring layout of a kart frame with the engine mounted.

  • Page 9: Installing The Water Cooling System

    Section 3.2 INSTALLING THE WATER COOLING SYSTEM Note: To install the belts it is necessary to remove the axle from one side of the kart. Once done slide the belts over the axle and reinstall the axle. (Installing a spare set of belts will eliminate removing the axle to replace a broken belt).
  • Page 10 Before installing the radiator attach the mount brackets. Fig. 4 Slide mount bar through the upper tube of each bracket. Add washer and rubber isolators to the end of each mount bar and tighten as shown in Fig. 4. Fig. 5 Install set screws in the upper tube of each bracket as shown in Fig.
  • Page 11 Fig. 6 With set screws facing out install the long bracket into the upper tabs on the radiator. Use a washer and M5x10 bolt as shown in Fig. 6. Fig. 7 Follow the instructions from Fig. 6 for the short bracket. Install them into the lower tabs as shown in Fig.
  • Page 12 Fig. 9 Mount the lower bracket to the chassis using an M6x70 bolt (not included) as shown in Fig.9. Leave loose for final positioning. Fig. 10 Mount the upper bracket to the bearing cassette or where best suited using an M6x70 bolt (not included) as shown in Fig.

  • Page 13: Installing The Header

    Fig. 12 The kit includes 2 water hoses that must be cut to fit.  Connect the first hose to the top of the radiator and to the top of the engine. (Depending on the seat size the hose may need to be cut and coupled behind seat;...

  • Page 14: Engine Mount Preparation

    Section 3.4 ENGINE MOUNT PREPARATION *If the engine mount is not drilled the engine bolt pattern is 102mm x 80mm. Fig. 2 Bolts should extend through the mount ¾”. Turn the engine upside down and install the engine mount as shown in Fig. 2. Tighten bolts in a cross pattern.

  • Page 15: Installing The Carburetor

    Section 3.5 INSTALLING THE CARBURETOR Fig. 1 Install the nut on to the cable adapter as shown in Fig.1. Fig. 2 Insert cable adapter through the throttle bracket and tighten with the nut as shown in Fig. 2. Fig. 3 Install the filter cup on to the front of the carburetor and tighten with bolts as shown in Fig.
  • Page 16 Fig. 4 Remove the two top screws over the throttle arm as shown in Fig. 4. Fig. 5 Install the throttle bracket and reinsert the two top screws as shown in Fig. 5. Fig. 6 Place the carburetor gasket over the two intake studs as shown in Fig.

  • Page 17: Installing The Chain

    Fig. 7 Install the carburetor on to the two intake studs as shown in Fig. 7. Fasten with the two nuts provided. Section 3.6 INSTALLING THE CHAIN Fig. 1 Align the rear sprocket with the clutch drum as shown in Fig. 1. Fig.

  • Page 18: Installing The Clutch Cover, Gear Plate Guard & Coil

    Fig. 3 Tighten the engine on to the chassis leaving approximately ½” free play as shown in Fig. 3. Section 3.7 INSTALLING THE CLUTCH COVER, GEAR PLATE GUARD & COIL Fig. 1 Add the medium silver washer to the long side of the rubber isolator and insert through the clutch cover.
  • Page 19 Fig. 3 Place medium silver washers on the other sides of the rubber isolators as shown in Fig.3. Fig. 4 Place the coil on to the isolators then add the ground wire to the top isolator. Add a small silver washer to each of the isolators followed by two nuts as shown in Fig.

  • Page 20: Installing The Electrical System

    Fig. 6 Attach the clutch cover assembly and fasten with bolts provided as shown in Fig. 6. Attach the ground wire from the coil to the engine as shown in Fig. 6.1. Fig. 6.1 Section 3.8 INSTALLING THE ELECTRICAL SYSTEM Fig.
  • Page 21 Fig. 2 Position the plastic mounts onto the bottom of the battery box so they attach to the brackets as shown in Fig. 2. Fig. 3 Place the battery box on to the chassis and add the bottom bracket. Secure with the two bolts provided.
  • Page 22 Fig. 6 Fasten the top strap with the bolt and nut provided as shown in Fig.6. Fig. 7 Connect the starter wire from the engine to the harness as shown in Fig. 7. Fig. 8 Connect the stator wire to the harness as shown in Fig.
  • Page 23 Fig. 9. Fig. 10 Connect the coil wire to the harness as shown in Fig. 10. NOTE IF YOU HAVE A 2016 PRD FIREBALL 125CC ENGINE PLEASE CONNECT THE WIRING HARNESS TO THE SWITCH PLATE AS SHOWN...
  • Page 24 Fig. 11 Connect the on/off switch to the harness as shown in Fig. 11. (Notice the orange wire is longer and goes on the silver spade connector) Fig. 12 Connect the on/off switch pigtail to the harness as shown in Fig. 12. Fig.
  • Page 25 Fig. 14 Install the switch bracket in between the steering hub and the steering wheel as shown in Fig.14. Fig. 15 Unscrew the rubber cover on the starter button. Insert the starter button through the larger hole on the switch bracket as shown in Fig.15.
  • Page 26 Fig. 17 Insert the on/off switch through the smaller hole on the switch bracket as shown in Fig.17. Fig. 18 Fasten the on/off switch with the nut provided as shown in Fig.18. Fig. 19 Attach the two red wires to the positive (+) terminal on the battery as shown in Fig.
  • Page 27 Fig. 20 Attach the black wire to the negative (-) terminal on the battery as shown in Fig. 20. Fig. 21 Connect the CDI box (the larger of the two) to the harness as shown in Fig.21. Fig. 22 Connect the blue wire from the primary harness to the blue wire on the secondary harness as shown in Fig.
  • Page 28 Fig. 23 Connect the relay to the harness as shown in Fig. 23. Fig. 24 Use a zip-tie or black electrical tape to secure the harness to the chassis as shown in Fig. 24. Note: Do not over tighten zip-ties as wire failure will occur.
  • Page 29 Fig. 25 Velcro the CDI and Relay (shown in Fig.25) to the battery or bolt to the seat. Fig. 26 Twist on the spark plug cap to the coil wire as shown in Fig. 26.
  • Page 30 COMPLETE ELECTRICAL SYSTEM DIAGRAM H01: On/Off H03: Switch H05: Yuasa H07: Battery Box H09: Relay Switch Bracket Battery H02: Starter H04: Wire H06: Battery H08: 7.5AMP Fuse for H10: CDI Button Harness Terminal Wire Harness Modular...

  • Page 31: Installing The Airbox And Exhaust

    Section 3.9 INSTALLING THE AIRBOX AND EXHAUST Fig. 1 Attach the rubber boot of the airbox to the filter cup as shown in Fig. 1. Fig. 2 Secure the rubber boot with the hose clamp provided as shown in Fig. 2. Fig.
  • Page 32 Fig. 4 Place the insulating sleeve over the connector tube as shown in Fig. 4. Fig. 5 Cut back the insulating sleeve ¾” shorter than the connector tube as shown in Fig. 5. Fig. 6 Insert the exhaust into the header as shown in Fig.
  • Page 33 Fig. 7 Attach the springs from the header to the exhaust as shown in Fig. 7. Fig. 8 Attach the two springs around the pipe to the pipe cradle as shown in Fig. 8.

  • Page 34: Fuel And Oil

    Section 4 FUEL AND OIL Use premium or race gasoline with 92 octane or greater mixed with 10 ounces of oil to the gallon. Straight castor oil is highly recommended or a synthetic oil with castor oil blend. Please note straight castor oil will leave a deposit on the top of the piston and head.

  • Page 35: Starting And Stopping The Engine

    Section 6 STARTING AND STOPPING THE ENGINE START POSTION STOP POSITION To start the engine pull switch outwards to the start position, press the starter button while choking the carburetor by covering the airbox tubes with your hand. When the engine starts remove your hand from the airbox tubes.

  • Page 36: Maximum Rpm

    Section 8 MAXIMUM RPM The CDI box is set to 0° advance at 16,000 RPM’s and will not produce power beyond this point. It is recommended that gearing be used not to exceed 15,500 RPM’s to ensure adequate power while in “the draft”. RPM’s are limited to increase the longevity of the engines life. Section 9 INTAKE SILENCER/AIRBOX Ensure the intake silencer is mounted on the engine two (2) inlet holes are pointing up (12:00)

  • Page 37: Dry Centrifugal Clutch

    Section 11 DRY CENTRIFUGAL CLUTCH The clutch and all the components including the ring gear/flywheel should be checked every five (5) hours. If any ware, damage or cracking is detected all such parts should be replaced immediately. NEVER use a cracked flywheel this could result in bodily injury. Check clutch if metal to metal noise is heard.
  • Page 38 (PRD-0146). 6. Heat the clutch center to loosen the loctite using a hair dryer or heat gun. 7. Install the clutch puller (PRD-7193) and remove the clutch. Do not use a hammer on the clutch puller. 8. Remove the 3 M6x16mm bolts (D17) to remove clutch center from the gear plate using a 10mm socket or wrench.

  • Page 39: Battery

    Section 13 BATTERY Twelve (12) volt. Always wear safety glasses and plastic gloves when initially adding the battery electrolytes as well as performing maintenance. The battery must be charged at all times. Use 1.8 amp charger. Full charge time at this rate is ten (10) hours.

  • Page 40: Electrical System Warnings

    The eyelet connector must be in contact with the lamination on the coil. Always use a PRD-Fireball coil. Use of a non-PRD coil may cause damage to the CDI. The ignition system requires the use of a resistor spark plug cap or plug. The resistor valve must be >/= 5kohm.

  • Page 41: Spark Plug

    Section 15 SPARK PLUG The NGK-BR10EG spark plug which sits in the middle of the heat range is supplied with each engine. This spark plug is excellent for break in and most operational needs. Other heat range plugs may be used depending on weather, fuel and track layout. (table below) NGK-BR9EG PLUG HOT HEAT RANGE NGK-BR10EG PLUG...

  • Page 42: Gear Ratio

    Section 16 GEAR RATIO The following gear ratio chart should help determine what ratio is best for each track without abusing the engine. The engine is supplied with an eleven (11) tooth sprocket on the clutch. A ten (10) tooth sprocket is also available. REAR AXLE RATIO RATIO...

  • Page 43: Starter Removal And Assembly

    Section 17 STARTER REMOVAL AND ASSEMBLY Fig. 1 Remove two M6x35 bolts from the starter using an allen wrench as shown in Fig. 1. Fig. 2 Remove the starter from the engine as shown in Fig. 2. Fig. 3 Pull back the cover boot from the red wire and remove the screw as shown in Fig.
  • Page 44 Fig. 4 Remove the three housing retention bolts as shown in Fig. 4. Fig. 5 Hang on to the drive gear (red arrow in Fig. 5) and remove the housing as shown in Fig. 5. Fig. 6 Remove the armature as shown in Fig.
  • Page 45 Fig. 7 Remove the two screws and the brush retention plate as shown in Fig. 7. Fig. 8 Remove the rubber insulator from the brush terminal as shown in Fig.8. Fig. 9 Remove the silicone from both of the brush braids as shown in Fig. 9.
  • Page 46 Fig. 10 Remove the brush from the gear housing as shown in Fig. 10. Fig. 11 Install the new brush into the gear housing as shown in Fig. 11. Fig. 12 Reinstall the rubber insulator, the retention plate and fasten with the two screws as shown in Fig.
  • Page 47 Fig. 13 Remove the screw that holds in the second brush as shown in Fig. 13. Replace with new brush. Fig. 14 Pre-bend two metal strips to retain spring/brush assembly as shown in the bottom picture of Fig. 14. Insert one spring and one brush into its guide and retain it with the pre-bent clip as shown in Fig.
  • Page 48 Fig. 16 Insert the armature into the gear housing as shown in Fig. 16. Note: Be careful to not knock off the clips. Fig. 17 Remove the clips as shown in Fig.17. Be sure that the brushes are in contact with the copper part of the armature after removing the clips.
  • Page 49 Fig. 19 Replace the three housing screws with blue loctite as shown in Fig. 19. Fig. 20 Reinstall the red wire on to the brush terminal and fasten with the screw as shown in Fig. 20. Slide the rubber boot over terminal. Fig.

  • Page 50: General Maintenance Schedule

    Section 18 GENERAL MAINTENANCE SCHEDULE HOURS REQUIRMENT REPLACE Before use Exhaust springs on header Check status Exhaust springs on cradle Check status Silencer endcap Check screws Engine Sprocket Check wear Check alignment with axle sprocket Engine Chain Check tensioning and oil chain Battery Check status and charge...

  • Page 51: Recommended Engine Maintenance Schedule

    Section 19 RECOMMENDED ENGINE MAINTENANCE SCHEDULE HOURS REQUIREMENT REPLACE First 6-8 Top End Rebuild Base gasket Small end rod bearing Piston pin Circlips Piston & Ring All head o-rings Inspect Starter & brushes Replace if necessary Inspect Reeds Replace if necessary Inspect Starter ring gear/flywheel Replace if necessary Next 6-8...

  • Page 52: Troubleshooting

    Section 20 TROUBLESHOOTING SYMPTOMS POSSIBLE CAUSES SOLUTIONS Engine will not turn over Dead/low battery Check connections, charge or replace the battery Bad ground wire Check the connection and tighten Failed starter button Replace or check with tester Failed starter Rebuild starter Failed relay Replace relay Bad spark plug...

  • Page 53: Engine Storage

    Section 21 ENGINE STORAGE When the engine will be stored for an extended period of time the following preventative actions should be followed: Disconnect the battery and charge it periodically. Disconnect carburetor and clean it. Seal the engine inlet and exhaust with tape. Clean the outside of the engine and spray un-plated steel parts with a light coat of oil.

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