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Table of Contents
Related Manuals for IAME EASY-KART 2003
Summary of Contents for IAME EASY-KART 2003
- Page 1 EASY-KART ENGINES 2003 ASSEMBLY INSTRUCTIONS USER MANUAL MAN-028...
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Page 2: Table Of Contents
INDEX Page GENERAL DESCRIPTION OF THE ENGINE CHARACTERISTICS OF THE TaG ENGINES – OPERATIONAL LIMITS 1- Contents of the packing 2- Motor identification Number 3- Preparation and installation of the engine on the chassis 3.1 Exhaust header assembly 3.2 Preparation and installation of the motor-mount 3.3 Install the carburetor 3.4 Install the engine on the chassis 3.5 Install the clutch cover with H.T. -
Page 3: General Description Of The Engine
GENERAL DESCRIPTION OF THE ENGINE The “TaG” engines have been expressly designed and developed for the powering of karts for hobby racing on closed tracks, destined for this specific purpose. When designing this new line of engines, the technical solutions already adopted for the high performance engines were considered, in order to guarantee the highest reliability of components, under the condition that the operating limitations are respected. - Page 4 The carburetor is a diaphragm Tillotson carburetor with fixed jet on the High speed, integral fuel pump and filter and has an all position mounting. The battery (12 V- 7.2Ah) is a sealed type, without maintenance battery and is supplied already preassembled in the battery and Power Pack support box which can be easily adapted to all existing chassis.
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Page 5: Characteristics Of The Tag Engines – Operational Limits
2. OPERATIONAL LIMITS: Max RPM : 12500 RPM on 62cc. 15500 RPM on 100/125cc. ATTENTION: Never exceed the above limits. No obligation of IAME exists in case the above limits are exceeded. 3. CHARACTERISTICS VALID FOR EACH MODEL MOTORE 62 cc. -
Page 6: Contents Of The Packing
1- CONTENT OF THE PACKING Each engine of the TaG series is delivered with the under shown accessories which are preinstalled on the EASY-KART chassis. PISTON PORT REED VALVE ENGINE 62 cc. ENGINE 100/125 cc. EXHAUST Flexible Spring For Flexible Exhaust Fiber Strip Exhaut Header Exhaust Muffler... -
Page 7: Motor Identification Number
NOTE: In case of need for spares and when contacting the IAME Support Centers, please always refer to the Motor Identification Number and to the motor model. MAN-028... -
Page 8: Preparation And Installation Of The Engine On The Chassis
3- PREPARATION AND INSTALLATION OF THE ENGINE ON THE CHASSIS NOTE: In case the engine is supplied already assembled on the chassis, 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. -
Page 9: Preparation And Installation Of The Motor-Mount
PREPARATION AND INSTALLATION OF THE MOTOR MOUNT 3.2.1 DRILL 4 HOLES (DIAM 8.5mm) IN THE MOTOR MOUNT MOTOR MOUNT HORIZONTAL VIEW IN CASE THE SUPPLY INCLUDES THE ADDITIONAL MOTOR MOUNT MOTOR MOUNT HORIZONTAL VIEW MAN-028... -
Page 10: Install The Carburetor
3.2.2 BEFORE INSTALLING THE MOTOR MOUNT, POSITION THE ADDITIONAL MOUNT Fig.3 PLATE (IF INCLUDED IN THE SUPPLY) ON THE CRANKCASE (SEE FIG. 3). 3.2.3 INSTALL THE MOTOR MOUNT. MAKE 6 mm ALLEN WRENCH. SURE TO USE M8 ALLEN SCREWS WITH A LENGHT SUCH AS TO ENGAGE, IN THE Fig.4 CRANKCASE,... - Page 11 SCREWDRIVER 4.8 mm. 3.3.2 REMOVE 2 SCREWS 3.5mm ON THE Fig.6 CARB. PUMP (IN CORRESPONDENCE OF THE THROTTLE LEVER) (SEE FIG. 6). Fig.7 3.3.3 INSERT THE GAS BRACKET AND THE TWO SCREWS (SEE FIG. 7). 3 mm ALLEN WRENCH 3.3.4 INSTALL THE INTAKE SUPPORT –...
- Page 12 Fig.10 ATTENTION: WHEN REPLACING THE CARB GASKET ALWAYS MAKE SURE THAT THE GASKET IS INSTALLED SO THAT THE HOLE IN THE GASKET MATCHES WITH PRESSURE HOLES IN THE CARB. AND IN THE CRANKCASE: OTHERWISE THE ENGINE WON’T START. INSTALL THE CARBURETOR. N.2 NUTS M6 AND TWO WASHERS.
- Page 13 3.4.2 CHECK THE ALIGNMENT OF THE ENGINE SPROCKET AXLE SPROCKET (SEE FIG. 14). Fig.14 3.4.3 INSTALL THE CHAIN (PITCH: 7.775) (SEE FIG. 15). Fig.15 3.4.4 MOVE THE ENGINE ON THE RAILS AND OPTIMIZE THE CHAIN TENSION . ATTENTION: THE PLAY OF THE CHAIN MUST BE APPR. 15mm MEASURED IN THE SHOWN POINT (SEE FIG.
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Page 14: Install The Clutch Cover With H.t. Coil
5mm ALLEN INSTALL THE CLUTCH COVER WITH H.T. COIL 3.5.1 REMOVE THE 3 SCREWS M6 X 30 ON THE CRANKCASE (SEE FIG. 17) AND INSTALL THE CLUTCH COVER WITH H.T. COIL (SEE FIG.18). TORQUE THE 3 SCREWS AT 8 ÷ 10 Nm ATTENTION: ALWAYS MAKE SURE THAT THE GROUND CABLE ALWAYS CONNECTS THE COIL WITH... -
Page 15: Installation And Connection Of The Power Pack Box
ELECTRICAL CONNECTION (refer to the attached electrical schematic) INSTALLATION AND CONNECTION OF THE POWER PACK BOX. NOTE: THE POWER PACK BOX IS SUPPLIED ALREADY ASSEMBLED ON THE BATTERY SUPPORT (WITH BATTERY) CORRECT INSTALLATION FOLLOW THE UNDER SHOWN INSTRUCTIONS. 3.6.1 EXTRACT THE BATTERY FROM THE Fig.19 SUPPORT AFTER HAVING UNLACED THE BATTERY STRAP (SEE FIG. -
Page 16: Electrical Connections On The Engine
3.6.4 INSERT THE BATTERY STRAP (SEE FIG. 22). Fig.22 3.6.5 INSERT BATTERY WITH TERMINALS TOWARDS THE OUTSIDE (SEE FIG. 23). CONNECT THE BATTERY TERMINALS. SUGGESTION: NEVER CONNECT THE BATTERY UNTIL YOU ARE READY TO START THE ENGINE. SEAL THE BATTERY TERMINALS WITH PLASTIC TAPE TO AVOID THAT EVENTUAL VIBRATIONS MIGHT... - Page 17 3.7.3 FIX THE GROUND CABLE, FROM THE POWER-PACK, ENGINE CRANKCASE, BY MEANS OF THE PROPER THREADED HOLE (SEE FIG. 25). ATTENTION: THIS OPERATION EXTREMELY IMPORTANT UNCERTAIN GROUNDING COULD DAMAGE THE POWER PACK BOX BEYOND REPAIR. Fig.25 Fig.25 3.7.4 CONNECT THE TERMINALS (3 AND 4 WAYS) ON THE HARNESS FROM THE Fig.26 POWER PACK BOX WITH THE TERMINALS...
- Page 18 3.7.6 CHEK THE ELECTRIC STARTER Fig.29 CABLE FIXING (SEE FIG. COMPLETE THE FIXING OF THE HARNESS (SEE FIG. 30). ATTENTION : NEVER LET THE HARNESS GET IN TOUCH WITH THE GROUND OR WITH A ROTATING PART AS IT COULD BE DAMAGED BEYOND REPAIR.
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Page 19: Install The Intake Silencer
3.7.9 PUNCTURE INSULATING MATERIAL ON THE H.T. CABLE WITH THE END OF THE CAP SPRING SO THAT THE SPRING IS IN SURE CONTACT WITH THE INTERNAL WIRE (SEE FIG. 33). Fig.33 3.7.10 INSERT THE SPARK PLUG CAP ON Fig.34 THE SPRING (SEE FIG. 34). INSTALL THE SPARK PLUG AND THE CAP OVER THE SPARK PLUG. -
Page 20: Install The Exhaust
INSTALL THE EXHAUST NOTE: SEE SECTION 9 FOR RECOMMENDATIONS ON THE IDEAL LENGHT OF THE EXHAUST. 3.9.1 INSTALL THE FLEXIBLE (L= 65mm – FLEXIBLE COMPLETELY CLOSED) AND THE EXHAUST HEADER (SEE FIG. 37) AND CONNECT THE EXHAUST. Fig.37 3.9.2 INSTALL THE FIBER STRIP AROUND THE FLEXIBLE AND FIX WITH THE 3 SPRINGS (SEE FIG. -
Page 21: Gasoline And Oil
4- GASOLINE and OIL Use leaded or unleaded Premium Gasoline (96 to 98 Octane RON) mixed with oil at 6% -(16:1). Use oils containing Castor Oil which guarantees an optimized lubrication at high temperatures. As on the other hand, use of Castor Oils creates gummy residues which give origin to carbon deposits, it is necessary to check and clean, at least every 5 ÷... -
Page 22: Carburetor Adjustment Guide
5- CARBURETOR ADJUSTMENT GUIDE ( I ) IDLE SPEED REGULATION SCREW FIXED HIGH SPEED JET ( L) LOW SPEED MIXTURE SCREW 1 T.O. RICH LEAN ¼ ¾ T.O. T.O. ½ T.O. TURNS OPEN The carburetors are originally supplied with a fixed jet on the High speed. The screws L and I are pre-set to start and run the engine. - Page 23 NOTE: (L) may need to be fine tuned again after a jet change. If so proceed as above. PROCEDURE FOR CHANGING FIXED SIDE JET 1. Remove sealing screw and gasket using a flat ended screwdriver turning anti-clockwise (see fig.1) Fig. 1 2.
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Page 24: Starting And Stopping The Engine
The engines are supplied with the following carburetors and kits of jets: Engine (cc) Carburetor HL 385 A HL 384 A HL 384 B Jet kit (P.N.) 10971 10972 10973 A Composition of Lean jet 0.73 0.83 0.87 Normal on 0.74 0.85 0.88... -
Page 25: Inlet Silencer
ATTENTION: Once the break-in is over and the engine is cold, check the torque of the exhaust header nuts as, during the break-in, the nuts tend to become loose (refer to the attached table). 8- INLET SILENCER Make sure that the inlet holes on the filter are towards the front of the kart and that they are not plugged. -
Page 26: Centrifugal Clutch
Having fixed a sprocket ratio, it could be necessary to improve the engine performance either at low or at high RPM. This could be achieved by modifying the exhaust lenght. In general, by shortening the total exhaust lenght an improvement at high RPM is achieved and vice versa, by lenghtening the exhaust lenght the low RPM is improved. - Page 27 ATTENTION: In case the friction material has been totally worn out and there has been a metal contact between the clutch body and the clutch drum, it is necessary to replace the clutch drum. See drawing. 11- INSTRUCTIONS FOR THE DISASSEMBLY / ASSEMBLY OF THE CLUTCH ATTENTION: The following operations can be performed by a skilled mechanic under the conditions to have available the dedicated tools shown on the text, otherwise it...
- Page 28 OPERATIONS TOOLS Clutch disassembly 1. Remove the clutch cover (3 screws M6). Allen wrench 5mm – T type 2. Remove the spark plug and replace with special tool Piston fitting : P.N. 10271 to prevent crankshaft from turning. 3. Remove nut (1 nut M10). 12 Point wrench - 17 mm 4.
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Page 29: Battery
12- BATTERY The battery (12 V–7.2 Ah) included in the supply is sealed and without maintenance. In order to lengthen the battery life it is necessary though to follow a few recommendations: When the tension drops below 12.6V it is necessary to recharge the battery. Max. -
Page 30: Spark Plug And Thermal Degree
13- SPARKPLUG AND THERMAL DEGREE The engine is supplied with a standard NGK BR10EG sparkplug which represents a good compromise between the needs of a good break-in and the racing needs in normal conditions. Use of different sparkplugs is possible and, as a general information, we are attaching a correspondence list among sparkplugs of other brands based on thermal degree which represents the capacity of the sparkplug to dissipate the internal heat. -
Page 31: Scheduled Maintenance
14- SCHEDULED MAINTENANCE Following some simple maintenance standards will allow the engine to perform more reliably and have a longer life. SCHEDULE COMPONENTS ACTIONS AND COMMENTS Before using Exhaust flexible Check status Exhaust springs Check status Exhaust strap Check status Exhaust muffler Check status and fixing Engine sprocket... -
Page 32: Troubleshooting
15- TROUBLESHOOTING Below are some common faults, their probable causes and suggested remedy: FAULTS PROBABLE CAUSE REMEDY Starter will not crank when Bad connections on starter cables. Check and tighten pushing the start button. Bad grounding Check connections and tighten Damaged cables Replace Battery connection loose... - Page 33 16- ENGINE PRESERVATION When engine is to remain unoperative for a long period it must be preserved as follows: Disconnect the battery and charge it periodically (see Par. 12) Disconnect carburetor and clean it Seal with tape the engine inlet and exhaust The external of the engine must be cleaned.
- Page 34 MAN-028...
- Page 35 MAN-028...