IAME 125 cc LEOPARD TaG engine Assembly Instructions And User's Manual
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IAME 125 cc LEOPARD TaG engine Assembly Instructions And User's Manual

IAME 125 cc LEOPARD TaG engine Assembly Instructions And User's Manual

2003 125 cc leopard tag engine
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125cc LEOPARD TaG engine
2003
ASSEMBLY INSTRUCTIONS
and
USER MANUAL
18/10/02 mod. C
MAN-016 D

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Summary of Contents for IAME 125 cc LEOPARD TaG engine

  • Page 1 125cc LEOPARD TaG engine 2003 ASSEMBLY INSTRUCTIONS USER MANUAL 18/10/02 mod. C MAN-016 D...

  • Page 2: Table Of Contents

    INDEX Page GENERAL DESCRIPTION OF THE "LEOPARD" 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 Install the water cooling system 3.2 Exhaust header assembly 3.3 Preparation and installation of the motor-mount 3.4 Install the carburetor...
  • Page 3 GENERAL DESCRIPTION OF THE "LEOPARD" ENGINE This engine of the "TaG" series (Touch and Go) has 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 used, in order to guarantee the highest reliability of components, when the operating limitations are respected.
  • Page 4 Automatic, dry, centrifugal 2. OPERATIONAL LIMITS: ?? Max. RPM : 15000 RPM ??Min. waterTemperature: 45°c ??Max. water Temperature: 90°c ATTENTION: Never exceed the above limits, no obligation of IAME exists in case the above limits are exceeded. 18/10/02 mod. C MAN-016 D...
  • Page 5 1- CONTENT OF THE PACKING Each Leopard engine is delivered with the under shown accessories: -125 cc LEOPARD- TaG engine EXHAUST ?? Flexible ?? Spring For Flexible ?? Exhaust Fiber Strip ?? Exhaut Header ?? Exhaust Muffler INDUCTION ?? Tillotson Carburetor ?? Intake Silencer ?? Intake Silencer Support ?? Accelerator Cable Bracket...

  • Page 6: 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. 18/10/02 mod. C...

  • Page 7: 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 8 INSTALL THE BELTS AND TENSION (SEE FIG. 4). Fig.4 BEFORE INSTALLING THE RADIATOR PREASSEMBLE THE FOLLOWING COMPONENTS INSERT THE RUBBER DAMPENERS INTO RUBBER DAMPENER THE FIXING HOLES OF THE RADIATOR AND INSERT THE SPACERS (SEE FIG. 5). SPACER Fig.5 INSERT THE BUSHES INTO THE RADIATOR SUPPORT BRACKET.
  • Page 9 UPPER SUPPORT BRACKET SUPPORT BRACKET SCREW M6X90 RADIATOR, AND ALSO INSERT THE UPPER SUPPORT BRACKET (SCREWS M6X90 AND M6X85 WITH NUTS). PLACE RADIATOR LOWER FIXING CLAMP SPACER RADIATOR SUPPORT BRACKET (SCREW SPACER M8X45 WITH NUT) (SEE FIG. 7). SCREW M6X85 Fig.7 RADIATOR LOWER FIXING CLAMP PLACE THE LOWER FIXING CLAMP ON THE...
  • Page 10 CONNECT THE SECOND HOSE BETWEEN THE FITTINGS ON THE RADIATOR OUTLET AND THE PUMP INLET. CONNECT THIRD HOSE BETWEEN THE FITTINGS ON THE PUMP OUTLET AND THE ENGINE INLET (SEE FIG. 10). TIGHTEN WITH STEEL CLAMPS. Fig.10 BEFORE STARTING THE ENGINE FOLLOW THESE RECOMMENDATIONS: ?? Unscrew the cap on the radiator and loosen the breather plug on the engine head.

  • Page 11: Exhaust Header Assembly

    EXHAUST HEADER ASSEMBLY NOTE: THE ENGINE IS SUPPLIED WITH THE EXHAUST GASKET AND NUTS ALREADY INSERTED. WHEN THE SHIPMENT IS MADE AN EXHAUST COVER TO PROTECT THE INTERNAL PARTS. 3.2.1 REMOVE THE NUTS AND THE EXHAUST COVER. Fig.1 3.2.2 MAKE SURE THE EXHAUST GASKET IS SEATED INSTALL EXHAUST...

  • Page 12: Install The Carburetor

    3.3.2 BEFORE INSTALLING MOTOR MOUNT, POSITION THE ADDITIONAL MOUNT Fig.2 PLATE ON THE CRANKCASE (SEE FIG. 2). 3.3.3 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.3 CRANKCASE, THREADED...
  • Page 13 SCREWDRIVER 4.8 mm. 3.4.2 REMOVE 2 SCREWS 3.5mm ON THE Fig.5 CARB. PUMP (IN CORRESPONDENCE OF THE THROTTLE LEVER) (SEE FIG. 5). Fig.6 3.4.3 INSERT THE GAS BRACKET AND THE TWO SCREWS (SEE FIG. 6). 3 mm ALLEN WRENCH 3.4.4 INSTALL THE INTAKE SUPPORT –...
  • Page 14 Fig.9 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 15: Install The Clutch Cover With H.t. Coil

    3.5.4 MOVE THE ENGINE ON THE RAILS AND OPTIMIZE THE CHAIN TENSION . ATTENTION: THE PLAY OF THE CHAIN MUST BE APPR. 15mm (½÷¾ inch) MEASURED IN THE SHOWN POINT (SEE FIG. 13) 15mm Fig.13 3.5.5 TORQUE THE CLAMP SCREWS 5mm ALLEN INSTALL THE CLUTCH COVER WITH H.T.

  • Page 16: 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) . FOR A CORRECT INSTALLATION FOLLOW THE UNDER SHOWN INSTRUCTIONS. 3.7.1 EXTRACT THE BATTERY FROM THE Fig.16 SUPPORT AFTER HAVING UNLACED THE...
  • Page 17 3.7.4 INSERT THE BATTERY STRAP (SEE FIG. 19). Fig.19 3.7.5 INSERT BATTERY WITH TERMINALS TOWARDS THE OUTSIDE (SEE FIG. 20). 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 DISCONNECT...
  • Page 18 3.8.3 FIX THE GROUND CABLE, FROM THE POWER-PACK, ON THE ENGINE CARTER, BY MEANS OF THE PROPER THREADED HOLE (SEE FIG. 22). ATTENTION: THIS OPERATION EXTREMELY IMPORTANT UNCERTAIN GROUNDING COULD DAMAGE THE POWER PACK BOX BEYOND REPAIR. Fig.22 3.8.4 CONNECT THE TERMINALS (3 AND 4 WAYS) ON THE HARNESS FROM THE Fig.23 POWER PACK BOX WITH THE TERMINALS...
  • Page 19 3.8.6 CHEK ELECTRIC STARTER Fig.26 CABLE FIXING (SEE FIG. COMPLETE THE FIXING OF THE HARNESS (SEE FIG. 27). ATTENTION : NEVER LET THE HARNESS GET IN TOUCH WITH THE GROUND OR WITH A ROTATING PART AS IT COULD BE DAMAGED BEYOND REPAIR.
  • Page 20 3.8.9 INSERT THE SPARK PLUG CAP ON Fig.30 THE SPRING (SEE FIG. 30). INSTALL THE SPARK PLUG AND THE CAP OVER THE SPARK PLUG. INSTALL THE SPARK PLUG INSTALL SPARK PLUG MAKING SURE THAT THE SPRING IN THE CAP IS WELL INSERTED IN THE SPARK PLUG.

  • Page 21: Install The Exhaust

    3.10 INSTALL THE EXHAUST NOTE: SEE SECTION 9 FOR RECOMMENDATIONS ON THE IDEAL LENGHT OF THE EXHAUST. 3.10.1 INSTALL THE FLEXIBLE (L= 65mm – FLEXIBLE COMPLETELY CLOSED) AND THE EXHAUST HEADER (SEE FIG. 33) AND CONNECT THE EXHAUST. Fig.33 3.10.2 INSTALL THE FIBER STRIP AROUND THE FLEXIBLE AND FIX WITH THE 3 SPRINGS (SEE FIG.

  • Page 22: Gasoline And Oil

    4- GASOLINE and OIL Use leaded or unleaded Premium Gasoline (92 RON+MON ) 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 23: Carburetor Adjustment Guide

    5- CARBURETOR ADJUSTMENT GUIDE ) THROTTLE ( H ) HIGH SPEED FUEL MIXTURE SPEED SCREW ( L ) LOW SPEED FUEL MIXTURE SCREW 1 T.O. RICH LEAN ¼ ¾ T.O. T.O. ½ T.O. T.O. = TURNS OPEN Normally the correct setting of the mixture screws is the following: ? ? L (close the screw completely and then open): 1 ¼...

  • Page 24: Starting And Stopping The Engine

    6- STARTING AND STOPPING THE ENGINE Press the green button on the Power Pack . If the engine can’t be started within 5 seconds (check that gas gets to the carb.) interrupt and try again after 15 seconds. Shorts and frequent tries are better than long ones.

  • Page 25: Exhaust System

    9- EXHAUST SYSTEM Before every test, make sure that the flexible is not damaged. Replace if necessary. ATTENTION: In case the flexible is damaged, metallic particles could be sucked in the engine and cause a seizure. Always make sure that the springs are well hooked and in place. In case of breakage, replace the broken spring.
  • Page 26 ATTENTION: Once the engine is started, avoid useless accelerations which can overheat and deteriorate the clutch. Oil the chain before each tests, immediately after each race or test, check the engine sprocket. Replace if necessary. A bad alignment of the engine sprocket with the axle sprocket or the lack of oil will damage the chain and sprocket.
  • Page 27 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 is necessary to apply to an Authorized Service Center. Refer to the following drawing during the operations.

  • Page 28: Battery

    Before assemblying the clutch, wash with diluent the shaft taper, the connecting hole on the clutch body, the clutch drum and the starter ring. Clutch assembly ? ? 10 mm socket 1. Install the starter ring on the clutch body by matching the 3 holes and the dragging pin.

  • Page 29: Spark Plug And Thermal Degree

    ATTENTION: Always connect the - (negative) terminal before and the + (positive) terminal after. Always disconnect the battery in opposite order. ? ? Recharge the battery at least once every 6 months. ? ? Never put the battery in contact with solvents, gasolines, oils, plastifiers or rags containing such elements.

  • Page 30: Choice Of The Best Sprocket Ratio

    The operating limit for the Leopard engine is 15000 RPM. ATTENTION: Never exceed the above limit. No obligation of IAME exists in case the above limit is exceed. In case the user wishes to optimize on the...
  • Page 31 Tab.1 Sprocket Sprocket Teeth n° - Engine sprocket Teeth n° - Engine sprocket ratio ratio Teeth n° - Teeth n° - axle sprocket axle sprocket 7,20 6,55 8,30 7,55 7,30 6,64 8,40 7,64 7,40 6,73 8,50 7,73 7,50 6,82 8,60 7,82 7,60 6,91...
  • Page 32 18/10/02 mod. C MAN-016 D...

  • Page 33: Scheduled Maintenance

    15- 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 34: Troubleshooting

    16- 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 35 17- 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 36 18/10/02 mod. C MAN-016 D...
  • Page 37 18/10/02 mod. C MAN-016 D...

  • Page 38: Wiring Diagram

    WIRING DIAGRAM Assembly Instructions & User Manual ? 2001 by IAME joint stock Comp. Edition , November 2000 All rights reserved. Any reprinting or Unauthorized use without the written Permission of IAME joint stock Comp. Is expressly prohibited 18/10/02 mod. C...

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