Parilla Leopard Manual - Acceleration Kart Racing
Contents
1. 925 948 970 992 10 5 107 sar aso 93 935 957 1023 923 944 966 988 1010 130 132 134 1360 1380 140 142 144 1460 148 150 152 L ce GJ C ec Kes 8 o9 Co oi Ca 00 eo jlololoa 0 d C ce co c a ue oo SH 4 un pil Jan LD oo III 4 Ch cmq cm e Ca ER LA 4 C h m 71 w hl S Ia Oy co 154 6 96 7 18 7 61 782 804 825 846 8 68 889 9 11 9 32 9 54 975 9 96 iso see 730 751 772 esr ee 920 sai 963 see 15800 1679 8 04 670 712 732 758 773 794 815 8 56 877 918 938 956 662 682 725 744 764 7 84 sos 825 866 856 906 927 947 74 734 ves 775 ves e ess 855 875 855 936 LOTEC OEE2. LEOPARD 125 RL engine ASSEMBLY INSTRUCTIONS amp USER MANUAL MAN 048 ING INDEX Page GENERAL DESCRIPTION OF THE ENGINE 1 CHARACTERISTICS OF THE LEOPARD ENGINE OPERATIONAL LIMITS 2 1 Contents of the packing 2 2 Motor identification Number 4 3 Preparation and installation of the engine on the chassis 3 1 Installation sketch of the engine on the chassis 5 3 2 Install the water cooling system 6 3 3 Exhaust header assembly 10 3 4 Preparation and installation of the motor mount 10 3 5 Install the carburetor 11 3 6 Install the engine on the chassis 13 3 7 Install the clutch cover with coil 14 3 8 Electrical connections 15 3 9 Installation of the intake silencer 20 3 10 Install the exhaust 21 4 Gasoline and Oil 22 5 Carburetor Adjustment guide 23 6 Starting and stopping the engine 24 7 Engine break in 25 8 RPM limitation 25 9 Inlet silencer 25 10 Exhaust system 26 11 Centrifugal clutch 26 12 Instructions for the assembly disassembly of the clutch 28 13 Battery 29 14 Warnings on the electrical system 30 15 Spark plug and thermal degree 31 16 Choice of the best sprocket ratio 32 17 Replacement of the starter brushes 35 18 Scheduled maintenance 41 19 Troubleshooting 42 20 Engine and accessories preservation 43 43 21 Fastener Torque Table Wiring diagram MAN 048 ING GENERAL DESCRIPTION OF THE ENGINE This engine of the TaG series Touch and
3. 3E m m CO e un c o TAT 7 09 725 747 7 67 7 86 825 8 44 864 883 903 co Hi en e o 34 MAN 048 ING 17 REPLACEMENT OF THE STARTER BRUSHES omme menus DISASSEMBLE THE STARTER UNLOOSE THE SCREW M6X30 ON THE STARTER SUPPORT see Fig 1 bmm ALLEN WRENCH T TYPE REMOVE THE STARTER SUPPORT 3 SCREWS M6X25 see Fig 2 bmm ALLEN WRENCH T TYPE UNSCREW N 3 SCREWS M6x35 see Fig 3 5mm ALLEN WRENCH T TYPE REMOVE STARTER see Fig 4 35 MAN 048 ING OPENING THE STARTER REMOVE THE PLASTIC CLAMP AND UNSCREW THE SCREW 4 FIXING THE INPUT CABLE TO THE STARTER see Fig 5 SCREWDRIVER UNSCREW 3 SCREWS 5 see Fig 6 SCREWDRIVER 36 MAN 048 ING REMOVE DRUM FROM STARTER KEEPING ROTOR IN ITS SEAT BE SURE TO HOLD THE ROTOR ON ITS TOOTHED SIDE TO PREVENT BRUSHES FROM FALLING OUT FROM THEIR SEAT see Fig 7 REMOVE ROTOR FROM STARTER HEAD see Fig 8 ATTENTION WHEN EXTRACTING ROTOR THE BRUSHES MAY SPRING OUT FROM THEIR SEATS REPLACING THE BRUSH UNSCREW THE 2 SCREWS M4 D RETAINING THE PLATE E see Fig 9 SCREWDRIVER REMOVE THE LITTLE RUBBER CAP see Fig 10 PLIERS OUR SUGGESTION SLIGHTLY OIL THE TIN PLATE TERMINAL END TO MAKE EASIER THE EXTRACTION OF THE LITTLE RUBBER CAP
4. the clutch body the clutch drum and the starter ring 1 Install the starter ring on the clutch body by matching 12 point wrench 10 mm the 3 holes and the dragging pin 3 screws M6 Torque at 10 Nm 90 in Ib Apply Loctite on the threads AN ATTENTION make sure to alwavs install the 7 mm dragging pin as otherwise the eventual kick backs could break the screws Insert key on shaft Install clutch body and the cone safety washer Install the 16 x 1 nut using the clutch wrench Clutch wrench 10270 24 mm socket ATTENTION turn counterclockwise as nut has Torque at 40 50 Nm 350 440 in Ib left thread 5 Install the internal washer ATTENTION install washer with bevel towards internal part of engine Clean the roller cage and grease it before installing it on the crankshaft 6 Install the clutch drum and the external washer ATTENTION install washer with bevel towards internal part of engine 7 Install the piston fitting to prevent the shaft from Piston fitting P N 10271 turning and install the 10 mm nut 17 mm socket Torque at 30 40 Nm 265 350 in Ib 8 Install the clutch cover 3 screws M 6 Allen 5 mm Torque at 8 10 Nm 70 90 in Ib 13 BATTERY The battery 12 V 9 Ah is sealed and without maintenance In order to lengthen the battery life it is necessary though to follow a few recommendations u When the tension drops below 12 6V it is necessary to rechar
5. 16 1 e Induction Reed valve e Carburetor Membrane Tillotson e Cooling Water Ignition Digital with integrated rev limiter e Battery charge With integral generator e Electric start 12V 0 30 Kw e Clutch Automatic dry centrifugal Operational limits e Max RPM 17000 RPM with rev limiter e Min water Temperature 45 c e Max water Temperature 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 under shown e coil e HTcol e Spark plug cap Dual Lock fixing strap WATER COOLING SYSTEM Radiator e e Radiator support kit e Water hose kit e Complete pump group QuantitY 1 QD 1 2 MAN 048 ING ACCESSORIES EXHAUST SYSTEM CLUTCH COVER COIL COMPLETE ELECTRIC ASSEMBLY ADDITIONAL ENGINE PLATE STARTER BRUSHES KIT INTAKE SILENCER TILLOTSON CARBURETOR RADIATOR SUPPORT KIT COMPLETE PUMP GROUP WATER HOSE KIT RADIATOR 3 MAN 048 ING 2 MOTOR IDENTIFICATION NUMBER The official motor identification number can be found stamped in the lower left part of the crankcase next to the electric starter see fig The number normally includes letter followed by 4 digits there can be exceptions some special cases Other numbers stamped on the crankcase or other surfaces of
6. 37 MAN 048 ING REMOVE SILICONE FROM BRUSHES WITH SCREWDRIVER see Fig 11 REMOVE 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 IT WITH THE 2 SCREWS M4 see Fig 14 SCREWDRIVER 38 MAN 048 ING REPLACEMENT OF THE BRUSH B UNLOOSE THE SCREW M3 G see Fig 15 EXTRACT THE BRUSH FIX THE NEW BRUSH WITH SCREW M3 SCREWDRIVER CLOSING THE STARTER INSERT THE NEW BRUSH SPRING A INTO ITS SEAT INSTALL THE BRUSH KEEP THE 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 see Fig 16 INSTALL THE STARTER ROTOR BETWEEN THE BRUSHES AND CHECK THAT THEY ARE ALWAYS IN CONTACT WITH THE CYLINDRIC COPPER PART OF THE ROTOR EVEN WHEN THEY ARE RELEASED see Fig 17 ALL i OUR SUGGESTION TO IMPROVE THE BRUSHES LIFE SECURE THE LITTLE WIRES WITH SILICONE see Fig 18 39 MAN 048 ING CHECK THAT O RING 5 INSTALLED ON THE STARTER HEAD INSERT STARTER DRUM ON THE HEAD BEING CAREFUL TO PREVENT ROTOR FROM ROTATING AND TO PREVENT THE BRUSHES FROM FALLING OUT OF THEIR SEAT see Fig 19 SCREW THE 3 SCREWS M5 see Fig 20 SCREWDRIVER CHECK THAT THE STARTE
7. ON THE LOWER RADIATOR CLAMP AVAILABLE IN DIFFERENT DIAMETERS 28 30 32mm 2 SCREWS M6x12 AND FIX IT TO THE TONGUE ON THE RADIATOR SUPPORT BRACKET N 1 SCREW M8x20 WITH NUT SEE FIG 9 SCREW M6X90 RADIATOR FIXING BRACKET SCREW M6X12 LOWER FIXING CLAMP MAN 048 ING PLACE THE RADIATOR FIXING CLAMP ON THE CHASSIS SIDE RAIL BRAKE SIDE N 2 SCREWS M6x25 TIGHTEN THE BOLTS BY HAND SEE FIG 10 PLACE THE RADIATOR SO THAT THE HOLE ON THE RADIATOR BRACKET AND ONE OF THE UPPER HOLES ON THE BEARING SUPPORT BOX MATCH N 1 SCREW 8 SEE FIG 11 ONCE YOU FIND THE CORRECT POSITION TIGHTEN THE M6x25 SCREWS ON THE CLAMP TIGHTEN AT 8 10 Nm 70 90 in Ib THE KIT INCLUDES THREE RUBBER HOSES CONNECT THE FIRST HOSE TO THE FITTING ON THE RADIATOR INLET AND THE FITTING ON THE ENGINE OUTLET TIGHTEN WITH STEEL CLAMPS ON BOTH SIDES CONNECT THE SECOND 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 STEEL CLAMPS ON BOTH SIDES SEE FIG 12 BEFORE STARTING THE ENGINE FOLLOW THESE RECOMMENDATIONS Unscrew the cap on the radiator and loosen the breather plug on the engine head Fill the radiator until the water comes out from the plug on the head there is no air in the system now and the radiator is completely filled Tighten the cap the system contains
8. SEE FIG 5 3 5 3 INSERT THE GAS BRACKET AND THE TWO SCREWS SEE FIG 6 3 54 INSTALL THE INTAKE SUPPORT 2 SCREWS M5 X10 SEE FIG 7 3 5 5 INSTALL THE CARBURETOR SEE FIG 8 9 REMOVE THE TWO M6 NUTS FROM THE INLET MANIFOLD REMOVE THE PLASTIC PLUG FROM THE INLET MANIFOLD ATTENTION MAKE SURE THAT THE PRESSURE HOLE ON THE GASKET IS NOT PLUGGED SCREWDRIVER 4 8 mm Fig 5 12 MAN 048 ING ATTENTION WHEN REPLACING THE CARB GASKET ALWAYS MAKE SURE THAT THE GASKET IS INSTALLED SO THAT THE HOLE IN THE GASKET MATCHES WITH THE TWO 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 TORQUE AT 6 10 Nm 50 90 in Ib 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 SUGGESTION NEVER TORQUE COMPLETELY THE CLAMPS UNTIL THE CHAIN IS INSTALLED AND PROPERLY ALIGNED 3 6 2 CHECK THE ALIGNMENT OF THE ENGINE SPROCKET AND THE AXLE SPROCKET WITH A STRAIGHT EDGE SEE FIG 11 3 6 3 INSTALL THE CHAIN PITCH 7 775 SEE FIG 12 13 MAN 048 ING 3 6 4 MOVE THE ENGINE ON THE RAILS AND OPTIMIZE THE CHAIN TENSION THE PLAY OF THE CHAIN MUST APPR 15mm 27 inch MEASURED IN THE SHOWN POINT SEE FIG 13 3 6 5 TORQUE THE CLAMP SCREWS 3 7 INSTALL THE CLUTCH COVER W
9. appr 1 It of water It is advisable to put a small cup to recover water from the breather on the cap in case of boiling water After the engine run in check the water level in the radiator and top up if necessary 9 MAN 048 ING EXHAUST HEADER ASSEMBLY NOTE THE ENGINE IS SUPPLIED WITH THE EXHAUST GASKET AND NUTS ALREADY INSERTED WHEN THE SHIPMENT IS MADE AN EXHAUST COVER GASKET IS PROVIDED TO PROTECT THE INTERNAL PARTS 3 3 1 REMOVE THE 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 12 POINT WRENCH 10 mm OR OPEN WRENCH 10 mm TORQUE AT 11 Nm 80 100 in Ib y um 10 MAN 048 ING 3 42 BEFORE INSTALLING THE MOTOR MOUNT POSITION THE ADDITIONAL MOUNT PLATE ON THE CRANKCASE SEE FIG 2 SURE TO USE M8 ALLEN SCREWS WITH A LENGHT SUCH AS TO ENGAGE IN THE CRANKCASE A THREADED PORTION LENGHT OF 16 19 THE SCREW MUST PROTRUDE FROM THE PLATE FOR 16 19mm SEE FIG 3 AND DRAW PAG 10 4 ALLEN SCREWS M8 TORQUE AT 22 24 Nm 190 210 in Ib INSTALL THE CARBURETOR 3 5 4 INSTALL THE GAS CABLE CLAMP ON THE SUPPORT SEE FIG 4 12 POINT WRENCH 10mm Fig 4 11 MAN 048 ING 3 5 2 REMOVE 2 SCREWS 3 5mm ON THE CARB PUMP IN CORRESPONDENCE OF THE THROTTLE LEVER
10. 27 MAN 048 ING 12 INSTRUCTIONS FOR THE DISASSEMBLY ASSEMBLY OF THE CLUTCH ATTENTION The following operations can be performed by 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 1 Drum nut 5 Sprocket 9 Cone safety washer 2 External washer 6 Clutch drum 10 Clutch body 3 Roller cage 7 Internal washer 11 Starter ring 4 Screw 8 Locking nut 12 Screw OPERATIONS TOOLS Clutch disassembly 1 Remove the clutch cover 3 screws 6 Allen wrench 5mm T type 2 Remove the spark plug and replace with special tool Piston fitting 10271 to prevent crankshaft from turning 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 P N 10270 24 mm socket clutch wrench remove the 16x1 nut and the cone safety washer Turn clockwise as nut has left thread 6 Apply clutch puller on clutch and remove clutch with Clutch puller P N B 55614 C 12 point wrench 19mm 12 point wrench 19mm 7 Remove key from shaft 8 Remove the starter ring 3 viti 6 12 point wrench 10 mm 28 MAN 048 ING Before assemblying the clutch wash with diluent the shaft taper the connecting hole
11. CTION OF THE TERMINALS 3 8 14 ATTACH THE DUAL LOCK FIXING STRAP CLOSE TO THE STEERING COLUMN AND PLACE THE ELECTRONIC 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 THE FAIRING TO ATTACH THE CABLES WITH PLASTIC CLAMPS SEE FIG 34 3 8 16 ATTACH THE DUAL LOCK FIXING STRAP UNDER THE FRONT FAIRING CLOSE TO THE BATTERY AND PLACE THE FUSE HOLDER SEE FIG 35 NOTE CLEAN AND DEGREASE THE FAIRING FIXING SURFACE WHERE THE STRAP IS TO BE PLACED TO GUARANTEE THE BEST POSSIBLE STRAP ATTACHMENT 19 MAN 048 ING 3 8 17 PLACE THE WIRING HARNESS gt gt BATTERY TERMINALS UNDER IHE STRAP SEE FIG 36 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 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 e INSTALL THE SPARK PLUG TORQUE AT 20 26 Nm 175 230 in Ib INSTALL THE CAP ON THE SPARK PLUG INSTALL THE INTAKE SILENCER MAKE SURE THAT THE FILTER HAS THE INLET HOLES TOWARDS THE UPPER SIDE FIX THE FILTER ON THE CARB WITH A STEEL CLAMP AND THE FILTER TO THE CHASSIS SIDE RAILS WITH PLASTIC CLAM
12. E CLAMP N 2 SCREWS M6x12 AND PLACE THE CLAMPS ON THE REAR CROSS RAIL N 2 SCREWS M6x25 INSTALL THE PUMP ON THE BRACKET 1 SCREW M8x45 WITH WASHER AND NUT SEE FIG 2 TIGHTEN BY HAND THE SCREW ON THE PUMP LETTING IT FREE TO ROTATE FOR THE ALIGNMENT AND TENSIONING OF THE BELTS PUMP FIX BRACKET INSTALL ON THE AXLE THE DRIVING PULLEY N 2 CLAMPS AVAILABLE IN DIFFERENT DIAMETERS 30 35 40 50mm ALIGNING ITS RACE WITH THE DRIVEN PULLEY SEE FIG 3 FIX THE TWO CLAMPS WITH 2 SCREWS M5x22 TIGHTEN AT 6 8 Nm 50 70 in Ib TIGHTEN THE TWO SCREWS M6x25 ON THE PUMP FIXING CLAMPS AND THE SCREWS M6x12 ON THE PUMP FIXING BRACKET TIGHTEN 8 10 Nm 70 90 in Ib 6 MAN 048 ING INSTALL THE BELTS AND TENSION SEE FIG 4 TIGHTEN THE SCREW M8x45 TORQUE AT 18 22 Nm 160 190 in Ib INSERT THE 4 RUBBER DAMPENERS INTO THE FIXING HOLES ON THE RADIATOR SEE FIG 5 RUBBER DAMPENER PLACE THE RADIATOR SUPPORT BRACKET BETWEEN THE RADIATOR FIXINGS BY TILTING ONE END AND INSERTING IT THROUGH THE RUBBER DAMPENERS SEE FIG 6 NOTE OIL THE BRACKET ENDS AND THE DAMPENERS HOLES RADIATOR SUPPORT BRACKET 7 MAN 048 ING COMPLETE INSERTION OF THE RADIATOR SUPPORT BRACKET IN THE RUBBER DAMPENERS SEE FIG 7 AND 8 FIX THE RADIATOR SUPPORT BRACKET INSERTING ALSO THE RADIATOR FIXING BRACKET RADIATOR CAP SIDE N 1 SCREW M6x90 AND N 1 SCREW M6x85 WITH NUT INSTALL THE L SHAPE BRACKET
13. 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 The motor is a single cylinder using the two stroke principle The cylinder and the crankcase are in aluminium alloy The pressed in liner is made of centrifugated cast iron fully machined to guarantee the best possible stability The head is separated from the cylinder and secured by studs The crankshaft is built and supported by two ball bearings The crankshaft is of steel alloy hardened and tempered as is the connecting rod which runs on roller bearings The digital ignition with capacitive discharge is fed by a magneto which generates the spark energy for the starting of the engine supplies the advance timing through an integrated pick up and recharges the battery The ignition includes a digital electronic unit power pack 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 controls the advance the rev limitation and the engine start stop logic integrates the voltage regulator and the ignition circuit The starter relay Solid type SSR p
14. ITH H T COIL REMOVE THE 3 SCREWS 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 Ib AN ATTENTION ALWAVS MAKE SURE THAT THE GROUND CABLE ALWAVS CONNECTS THE COIL WITH THE ENGINE AN INADEQUATE GROUNDING COULD DAMAGE THE IGNITION BEVOND REPAIR THE POSITION OF THE H T COIL HAS BEEN CHOSEN TO BE AS FAR AS POSSIBLE FROM THE EXHAUST AS THE EXCESSIVE HEAT COULD DAMAGE THE COIL BEVOND REPAIR 14 MAN 048 ING ELECTRICAL CONNECTIONS Refer to the attached electrical schematic NOTE For a correct installation follow the under shown instructions 3 8 1 INSERT THE BATTERY STRAP IN THE BATTERY SUPPORT SEE FIG 16 10mm BOX WRENCH 3 8 2 PLACE THE BATTERY SUPPORT BOX Fig 17 IN THE FRONT OF THE CHASSIS UNDER THE FRONT FAIRING AND FIX IT WITH THE CLAMPS TO THE LOWER STEERING en COLUMN SUPPORT TUBES M6x25 M n SCREWS SEE FIG 17 TORQUE AT 8 10 Nm 70 90 in Ib THE SUPPORT BOX MUST BE FIXED WITH AT LEAST ONE BOLT FOR EACH CLAMP FIX THE BOX WITH MORE THAN ONE 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 3 8 3 INSERT THE BATTERY IN THE BOX AND FASTEN WITH THE BATTERY STRAP SEE FIG 18 POSITION THE BATTERY TERMINALS AS SHOWN ON THE FIGURE ATTENTION PAY ATTENTION NOT TO SHORT CIRCUIT THE BA
15. PS SEE FIG 39 20 MAN 048 ING INSTALL THE EXHAUST NOTE SEE SECTION 10 FOR THE RECOMMENDATIONS ON THE IDEAL EXHAUST LENGHT 3 10 1 INSTALL 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 FLEXIBLE INSULATING SLEEVE 3 10 2 INSERT THE FLEXIBLE ON THE 2 EXHAUST HEADER AND FIX WITH THE 3 qu MA f SPRINGS SEE FIG 42 l RED Weu ME ETS 1 recs A ANA E T Au te PET hadd NA l m P quant aan m 1 THE ENGINE IS READY TO BE STARTED 21 MAN 048 ING 4 GASOLINE and OIL Use leaded or unleaded Premium Gasoline 92 RON MON mixed with oil at 6 16 1 2 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 10 hours the piston 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 carburetor before starting the engine Never use the electric starter to suck the gasoline as this would discharge the battery SUGGESTION Disconnect the plastic tube on the carb and the vent tube
16. R ROTOR ROTATES FREELY CONNECT THE INPUT WIRING TO THE STARTER WITH THE SCREW 4 see Fig 21 SCREWDRIVER 6 ASSEMBLING THE STARTER PLACE THE STARTER IN SEAT see Fig 22 OIL O RING TO MAKE EASIER INSTALLATION N 3 SCREWS TCH M6x35 TIGHTEN 8 10 Nm 70 90 in lb 5mm WRENCH T TYPE 40 MAN 048 ING 18 SCHEDULED MAINTENANCE Following some simple maintenance standards will allow the engine to perform more reliably and have longer life SCHEDULE COMPONENTS ACTIONS AND COMMENTS Before using Engine sprocket Check wear Check alignment with axle sprocket Engine chain Check status tensioning and oil chain Battery Check status and charge Cables and connectors Check status and connections Grounding of engine Check status and connections electronic box Engine mount and clamps Check torques Battery Disconnect Check status and oil chain External cleaning Every 5 10 hours Bendix assembly Remove cover see fig and clean internally Every 20 hours 41 MAN 048 ING 19 TROUBLESHOOTING Below are some common faults their probable causes and suggested remedy FAULTS PROBABLE CAUSES REMEDY Starter will not crank when connections on starter cables Check and tighten turning the key to RUN position Bad grounding Check connections and tighten Interruption on fuse Replace 5 strip fuse after checking for eventual reversal of ba
17. ROUND CABLE IN THE 472 HARNESS CLOSE TO THE COIL CABLE TO THE COIL BY MEANS OF THE M6 NUT WW k FIXING THE COIL SEE FIG 25 D TORQUE AT 8 10 Nm 70 90 in Ib ATTENTION THIS OPERATION IS EXTREMELY IMPORTANT AS AN UNCERTAIN GROUNDING COULD DAMAGE THE POWER PACK BEYOND REPAIR 3 8 9 CONNECT THE H T COIL CABLE TO THE HARNESS TERMINAL SEE FIG 26 ATTENTION FASTEN THE COIL CABLE WITH A PLASTIC CLAMP TO AVOID THAT EVENTUAL VIBRATIONS MIGHT DISCONNECT THE TERMINALS SEE FIG 27 17 MAN 048 ING 3 8 10 CUT THE DUAL LOCK FIXING STRAP AND ATTACH IT TO THE ELECTRONIC BOX THE STARTER FUSE AND THE FUSE HOLDER SEE FIG 28 FUSE HOLDER N ELECTRONIC BOX 3 8 11 CONNECT THE ELECTRONIC BOX TO THE 20 POLE TERMINAL IN THE WIRING HARNESS SEE FIG 29 CONNECT 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 TERMINALS 3 8 12 DRILL A 22mm HOLE IN THE SIDE OF FRONT FAIRING ENGINE SIDE AND INSERT THE STARTING ASSEMBLY SEE FIG 31 SECURE THE ASSEMBLY WITH THE THREADED RING NUT 18 MAN 048 ING 3 8 13 CONNECT THE CABLE FROM THE STARTING ASSEMBLY WITH THE 8 POLE TERMINAL IN THE WIRING HARNESS SEE FIG 32 ATTENTION MAKE SURE THAT THE FIXING TONGUES ARE PROPERLY INSERTED TO GUARANTEE THE BEST POSSIBLE CONNE
18. TTERY TERMINALS AS THE BATTERY COULD BE DAMAGED BEYOND REPAIR 3 8 4 POSITION THE WIRING HARNESS STARTING FROM THE ENGINE AND ALONG THE RAIL THE STEERING COLUMN AND UNDER THE FRONT PANEL FAIRING SEE FIG 19 TIGHTEN WITH PLASTIC CLAMPS ATTENTION NEVER LET THE HARNESS GET IN TOUCH WITH THE GROUND OR WITH ROTATING PARTS AS IT COULD BE DAMAGED BEYOND REPAIR 15 MAN 048 ING 3 8 5 CONNECT THE TERMINAL FROM THE IGNITION WITH THE 8 POLE TERMINAL ON THE HARNESS SEE FIG 20 CONNECT THE ONE WAY TERMINAL FROM THE ELECTRIC STARTER WITH THE ONE WAY TERMINAL ON THE HARNESS SEE FIG 21 MAKE SURE THAT THE TONGUES ARE PROPERLY INSERTED TO GUARANTEE BEST POSSIBLE CONNECTION OF THE TERMINALS 3 8 6 CHECK THE ELECTRIC STARTER CABLE FIXING SEE FIG 22 AND COMPLETE THE FIXING OF THE HARNESS SEE FIG 23 ATTENTION NEVER LET THE HARNESS GET IN TOUCH WITH THE GROUND OR WITH ROTATING PART AS IT COULD BE DAMAGED BEYOND REPAIR 16 MAN 048 ING 5 mm ALLEN 3 8 7 FIX THE HARNESS GROUND CABLE WITH THE EYELET TERMINAL 6 5mm ON THE ENGINE CRANKCASE BY MEANS OF THE PROPER THREADED HOLE SEE FIG 24 M6x12 SCREW TORQUE AT 8 10 Nm 70 90 in Ib ATTENTION THIS OPERATION IS EXTREMELY IMPORTANT AS AN UNCERTAIN GROUNDING COULD DAMAGE THE POWER PACK BEYOND REPAIR 10mm BOX WRENCH 3 8 8 FIX THE EYELET TERMINAL 7mm OF THE SECOND G
19. aintenance dry centrifugal clutch The following prescriptions if carefully followed will allow a long clutch life When starting the engine make sure that the brake pedal is fully pressed to avoid sudden accelerations 26 MAN 048 ING AN 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 Check the clutch Every 5 hours of use When metallic noises are heard inside the clutch fthe kart dragging speed exceeds 6000 RPM Everytime 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 the friction material see drawing is lower than 1 5mm on point A of the clutch or if the body diameter is lower than 82 5mm Whenever the external friction material in the A portion of the clutch is very rough wear or degradation of the friction material due to overheating ATTENTION In case the friction material has been totally worn out and there has been metal contact between the clutch body and the clutch drum it 15 necessary to replace the clutch drum See drawing
20. case it gets in touch with eyes wash and apply for medical assistance Carefully check the external case of battery and replace in case of breakages swellings of the case or of battery cover Before use clean the battery from dust and check that the terminals are not oxidyzed or damaged When the battery comes to an end never throw it in the garbage but deliver it to an authorized disposer 14 WARNINGS ON THE ELECTRICAL SYSTEM We are here listing the main warnings on the electrical system Please keep this in mind during the whole life of the engine 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 position every time the engine is stopped If the key is left in KEY position for a long time even if the engine is stopped the battery would be discharged completely 2 Never disconnect the ground cables with eyelets when the engine is in operation 3 Disconnecting the battery when the engine is in operation DOES NOT increase the engine performance Vice versa the ignition advance could become very irregular at low RPM thus reducing the performance 4 To fasten the eyelet terminal groundings of the wiring harness always use flat or open washers Never use tab washers 5 When disconnecting the connectors always press the fixing tongues Always pull the connectors t
21. d clean it with gasoline or solvent 25 MAN 048 ING 10 EXHAUST SYSTEM Before every test make sure that the flexible is not damaged Replace if necessary N 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 Never race the kart without the 3 springs in place as otherwise the exhaust pipe could vibrate beyond control Every 10 15 hours open the pipe end and make sure that the holes on the internal counter cone are not plugged The best performance is achieved with a total exhaust lenght of L 410 415 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 drawing To achieve this dimension the flexible supplied with the engine must be cut at a lenght of 65mm flexible completely closed 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 When testing never exceed in lenghtening or shortening the flexible by more than omm per time 11 CENTRIFUGAL CLUTCH The engine has a low m
22. dically see Sect 12 Disconnect carburetor and clean it Seal with tape 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 21 TORQUE VALUES M14 x 1 25 1 Spark plug Hex 20 8 20 26 175 230 8 x 1 25 Head and cylinder nut TS x 1 Exhaust nut M6 x 1 2 Carburetor attach nut Hex 101 M5 x 0 8 2 Coll attach screw Allen M5 x 0 8 ignition stator fixing screw Allen MIO x I ignition rotor fixing nut Hex M5 x I 4 Starter support fixing screw x TU ME x 1 Counter shaft support screw M6 x 1 Starter attach screw ME x 1 2 Clutch cover attach screw 10 70 80 MIO x 1 Clutch drum holding nut 17 30 40 265 350 M16 x I i Clutch fixing nut M5 x 0 8 J Engine sprocket fixing screw M6 x 1 J Starter ring fixing screw MO x I Crankcase fixing screw 6 ME x I J Add starter supp fix screw Allen 5 SU M6 x Additional supp locking screw Allen 5 T ZQ 80 43 MAN 048 ING S d nale ionian pu ci 4 pole ignition SS E mmm NE z leclronu of milk micrepracessor mi 0 pole c nnectar OELECOM ALTERNATIVE pole female I GELECOM 1 d 4 pole female c
23. emetry The following example should clarify the procedure for the optimization of the sprocket Assume to use the engine with Z 10 teeth engine sprocket and that during the preliminary track tests a Z 72 teeth axle sprocket has been used From table 1 with Z 10 as engine sprocket and Z 72 on the axle sprocket a ratio of 7 20 is found Make a few laps on the track and let us assume that you read 14 000 max engine RPM From the table 2 to achieve a max RPM of 16500 RPM operating limit for the Leopard engine sprocket ratio from 8 37 and 8 60 should be used having used during the tests a sprocket ratio of 7 2 and having achieved 14 000 RPM max From table 1 with these values a sprocket ratio of 10 84 10 86 should be used or having a Z 11 on the engine sprocket a ratio 11 92 should be used 33 MAN 048 ING SPROCKET RATIO TO ACHIEVE 16500 RPM Tab 2 SS ratio pr FA 731 75 77 79 Bl 85 8 89 91 23 or or oss Fur os as es s rep on sv sss 038 1038 oss vro 138 s 924 948 973 997 1022 1047 10 71 1096121 11 45 s 934 958 83 1007 102 1056 1080 1104 1128 821 945 ss 952 1016 1040 osa 1026 1172 o sos a ass are oz oos roce rore 1098 fazi 855 941 964 10 11 1034 1057 1081 Fase 682 905 928 951 974 997 1020 1043 1066 ses er sos sen oss
24. erwise the internal voltage regulator could be damaged 14 DO NOT connect batteries in parallel this might cause explosions and damages to the operator The recharge of the battery in normal conditions is guaranteed by the electrical system A few minutes of engine in operation are sufficient to recover the energy lost when starting the engine 15 In case the battery must feed other users Tachometer Telemetry etc first contact IAME to check the recharge capacity of the system 16 Modifications interventions and additions to the original electric system might cause malfunctions No obligation of IAME exists in this case SPARK PLUG AND THERMAL DEGREE The engine is supplied with a standard NGK BR10EG spark plug which represents a good compromise between the needs of a good break in and the racing needs in normal conditions Use of different spark plugs is possible and as a general information we are attaching a correspondence list among spark plugs of other brands based on thermal degree which represents the capacity of the spark plug to dissipate the internal heat The colour of the various parts of the spark plug more exposed to the combustion flames gives a good indication on the adequacy of the thermal degree and on the carburetion It is necessary though to understand which of the two parameters has to be changed and only the experience tells how to identify the most proper thermal degree of a spark plug as lean or rich mixtu
25. ge the battery Max allowed recharging current is 1 8A u ideal recharge is achieved with an average charging current of 0 8 1 A recharging time of appr 10 h and at an ambient temperature between 0 and 40 N ATTENTION An overcharge or an extremel uick charge with excessive current could damage the battery the battery would tend to swell Choose a battery charger with the following characteristics u Feed Tension 90 250 Vac 50 60 Hz Outlet Tension 15 V full charge 13 8 stand by Max outlet current 2A full charge During transportation or storage the battery could loose its charge due to self discharge 0 196 max per day Fully recharge battery before use 29 MAN 048 ING 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 The external case of the battery could be damaged Never press or bend or overheat by welding the battery terminals Other recommendations Pay attention not to have free fires upon or around the battery Never short circuit the terminals Never open the battery or throw it in the fire In case the electrolite diluted Sulfuric acid gets in contact with skin or clothes immediately wash with water In
26. h idle If R P M Slowly adjust clockwise If R P M BS id Trigger accelerator decreases increases Trigger accelerator Engine is now idling at max attainable R P M or slightly lower on rich side Adjust I counterclockwise until 2000 2500 R P M is reached Recheck L screw for optimum setting required Adjust H until best possible free speed is reached Turn clockwise for higher R P M Counterclockwise for lower R P M SEE TT SER E MM FT eegen 1 8 acceleration 9 P acceleration 23 MAN 048 ING 6 STARTING AND STOPPING THE ENGINE Starting is achieved by the starting key This is a 3 position key 1 STOP key can be removed 2 KEY 3 RUN STOP KEY HUN In STOP position the battery is disconnected and the engine stop signal is sent to the electronic box In KEY position the battery is connected to the system and the stop signal is removed In RUN position the battery is always connected and the electric starter operation signal is sent to the electronic box N ATTENTION The starting key assembly is supplied with two original keys We recommend to separate the keys and to keep one in a protected place In case of loss of both keys it is necessary to replace the complete assembly The starting procedure from STOP position is as follows A Turn the key to KEY position this connect the battery B Turn the key to RUN position to start the engine the electr
27. ic 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 running the key can be left both in the RUN or KEY position We suggest for pratical reasons to turn the key to KEY position this allows with a single tripping to stop the engine STOP position or to restart it in case the engine is stopped RUN position Note in case the engine is stopped with the key in RUN position to restart it turn the key to KEY position and then again to RUN position to activate the electric starter With the key in KEY or RUN position and if the engine is stopped to start the engine an external starter unit can also be used In case the engine cannot be started within 5 seconds check that gas gets to the carb interrupt and try again after 15 seconds Short and frequent tries are better than long ones To stop the engine turn the key to STOP position both from KEY 1 tripping or from RUN 2 trippings 24 MAN 048 ING ENGINE BREAK IN The break in of the engine must be performed following a few fundamental rules 1 Adjust the carburetion Start with an adjustment on the rich side 2 Warm the engine gradually for about 5 minutes at half throttle making some laps at low speed gently closing and opening the carb throttle if a tachometer is installed never exceed 11 000 12 000 RPM Never keep the same RPM for a long ti
28. me 3 Progressively increase the speed of the kart for 5 minutes at throttle opening Never keep the same RPM for a long time 4 Increase the speed for 5 minutes at max speed on the twisty parts of the circuit and making the engine rich at half straight cover with the hand for an instant the holes on the air filter keeping the throttle wide open 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 RPM LIMITATION The electronic box incorporates an RPM limiter which prevents the engine from exceeding 17000 RPM This limit cannot be exceeded otherwise the engine could be damaged by the extremely high RPM AN ATTENTION Do not keep the engine for a long time at the RPM at which the limiter is functioning This would cause malfunctions on the induction and damage the reed valve When choosing the sprocket ratio always refer to a maximum limit of 16500 RPM so that the incorporated limiter is not switched on continuously when the engine is running INLET SILENCER Make sure that the inlet holes on the filter are towards the upper side and that they are not plugged Make sure that the clamp on the carburetor is not loosen and that the filter is well fastened to the chassis Once a while clean the inside from oil deposits If necessary remove the rubber filter union an
29. o disconnect NEVER PULL THE CABLES 6 The electronic box and the starting relay must always be installed with their connector towards the bottom to avoid back water dampness or dirt in the connector body 7 Always correctly fix the coil with both screws make sure that the laminations pack on H T coil is connected to the engine with the grounding cable The eyelet connector must be directly in contact with the laminations pack on the H T coil Never use H T coils different than the original coil on the engine Use of different coil may cause damages to the electronic box 8 gt 30 MAN 048 ING 15 9 The digital assembly needs use of resistive spark plug cap or spark plug The resistor value must be equal or higher than 5 Kohm Avoid use of resistive H T cables 10 The electrical system is protected against battery polarity reversal When reversing the connectors on the battery the protection circuit activates the fuse as soon as the key is on KEY or RUN position The fuse must then be replaced 11 Replace the fuse after having disconnected both terminals on the battery Only use 5 strip fuse Use of fuses with higher amperage might damage the electronic box whenever the battery polarity is reversed 12 Only use sealed lead type batteries as specified by IAME Only use 12V batteries 13 Always disconnect the battery from the electrical system when recharging the battery with an external battery charger oth
30. on the tank and pressurize the vent tube until gasoline comes out from the tube on the carb Make sure there is no air in the tube Connect the tube on the carb and on the vent 22 MAN 048 ING 5 CARBURETOR ADJUSTMENT GUIDE I THROTTLE SPEED SCREW H HIGH SPEED FUEL MIXTURE L LOW SPEED FUEL MIXTURE 1 T O TURNS OPEN Normally the correct setting of the mixture screws is the following L close the screw completely and then open 1 1 close the screw completely and then open 1 1 4 Based on various factors as altitude ambient temperature etc it might be necessary to reset the carburetor to optimize the performance of the engine ATTENTION Never lean too much as lean mixture will overheat engine and cause seizure Do not force or L closed It may damage the precision machined orifice and render the carb unserviceable The adjustment of screw must be performed with warm engine H L Adjust T O from closed to Adjust T O from closed to approximately 1 Close by further 1 after contact with throttle lever approximately 1 T O Start the engine and warm it If RPM too high adjust I counterclockwise until clutch is disengaged Continue to turn clockwise Turn c c w until max R P M until max R P M is reached is reached Adjust further L A Adjust c c w fractionally for fractionally for ric
31. onnector i4 pale maie connectar SSR Starim rey Fiectramachanica Starting relay 5 ru Wire terminal with r m P Connactor SUMI M rhreogeg i dE IP MAFI j 55 4 T 8 pole male connecter L pole female connector SELECOM SELECOM Starter key assembly Starter had Connect fo fhe molar 4 female terminal plug WTA L1 F4 Fuse holder with fuse id tin ct ge MT terminal 8 3 Cail motor MAN 048 ING
32. res can generate the same final look which can also be achieved with a hot or cold spark plug See table An excessively warm spark plug shows the Extremely clear color porous look symptoms listed aside calcification of the electrodes and of the internal insulation ATTENTION Irregularities in the ignition preignition and Always use a warmer than standard spark detonation with tendency to perforate the top of plug with cold or rainy climates the piston Note Some of these symptoms can be achieved with lean mixtures A correct thermal degree shows Colour of the insulator end from yellow grey to dark brown for mixtures respectively lean or rich 31 MAN 048 ING An excessively cold spark plug shows the Insulator end and electrodes covered with black symptoms listed aside shady soot gnition difficulties ITTENTION Note a wet or oily electrode could also mean Always use a colder than standard an excessively rich mixture sparkplug with hot climates COMPARISON TABLE BASED ON THE THERMAL DEGREE HOT BOSCH CHAMPION WOSCS BRYEG NS4R WO7CS BRIOEG N52R WO6CS BRIIEG COLD 16 CHOICE OF THE BEST SPROCKET RATIO The life of an engine depends upon many factors but most of all upon the speed at which the engine is operated If an engine is normally operated at speeds higher than what recommended by the manufacturer the wears and stress of the various components con rods roller cages bearings e
33. rotected from short circuits supplies the power for the electric starter and is controlled by the power pack An RPM limiter integrated in the power pack prevents the engine from exceeding 17000 RPM during use The spark is generated also without a battery it is therefore possible in case of emergency to start the engine with an external starter unit With the starter key in RUN position the starter activates a Bendix type gear which engages the starter ring assembled on the clutch The engine is provided with an automatic dry centrifugal clutch with low maintenance and with interchangeable sprocket The carburetor is a diaphragm Tillotson carburetor with integral fuel pump filter and all position mounting capability The battery 12 V 9Ah is a sealed no maintenance battery and is supplied already preassembled in the battery support box which can be easily adapted to all existing chassis The exhaust included in the supply is already tuned for the best possible performance The engine is supplied with a kit which includes the radiator the pump water hoses and whatever necessary for the assembly on the kart 1 MAN 048 ING CHARACTERISTICS OF THE LEOPARD ENGINE OPERATIONAL LIMITS The characteristics of the engine are the following e Cycle OTTO 2 stroke e Original cubic capacity 123 67 cc e Original bore 54 00 mm e Max theoretical bore 54 28 mm e Stroke 54 00 mm e Lubrication Fuel oil mix 6
34. tc will be such as to drastically reduce the life of the engine itself It is therefore extremely important that the user respects the operating limits imposed by the manufacturer The operating limit for the Leopard engine is 17000 RPM and the RPM limiter is calibrated at this value A ATTENTION Never exceed the above limit No obligation of IAME exists in case the above limit 15 exceed In case the user wishes to optimize on the track the sprocket ratio in order to achieve the best possible performance without abusing the engine follow the under shown recommendations The engines are supplied with a 10 or 11 teeth sprocket pitch 7 775mm Table 1 shows the various ratios between the sprocket on the axle and the engine sprocket given the different axle sprockets 32 MAN 048 ING Tab 1 Sprocket ratio Sprocket ratio Teeht n Engine sprocket Teeth n Engine sprocket Teeth n 10 Teeth n 10 axle sprocket axle sprocket 75 62 86 80 782 780 709 s 80 mm 79 748 90 818 ma 80 72 am sv ma s 756 For the operation limit of 16500 RPM the following table Tab 2 has been prepared SUGGESTION During the track tests we recommend use of tachometer recording the max obtained engine RPM Use sparkplug caps with a resistance of 5KO to avoid eventual interferences between the engine ignition and the tachometer and or tel
35. the motor refer to various manufacturing processes and do not identify the motor 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 4 MAN 048 ING 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 Whenever the engine or a component is disassembled it is necessary to always follow the under shown instructions for proper reassembly 3 1 INSTALLATION SKETCH OF THE ENGINE ON THE CHASSIS e N Ze C i x ae Es aa gt ut LM 5 De fu ka P RK MAN 048 ING 3 2 INSTALL THE WATER COOLING SYSTEM NOTE To install the water pump belts it is necessary to remove the rear axle REINSTALL THE REAR AXLE AFTER HAVING INSERTED TWO BELTS SUGGESTION INSTALL OTHER TWO BELTS AS SPARES AND FIX THEM WITH TAPE TO THE AXLE INSTALL THE WATER PUMP 1 SCREW M8x45 WITH WASHER AND NUT ON THE PUMP BRACKET ON THE REAR CROSS RAIL SEE FIG 1 TORQUE AT 18 22 Nm 160 190 in Ib IN CASE THERE IS NO BRACKET FOR THIS PURPOSE IT IS NECESSARY TO INSTALL THE PUMP ON REMOVABLE CLAMPS AVAILABLE IN DIFFERENT DIAMETERS 228 30 32mm ASSEMBLE THE PUMP FIXING BRACKET ON TH
36. ttery polarity Battery connections loose Check and tighten Battery discharged Recharge battery Starter failure Overhaul starter Relay failure Replace relay Apply to Authorized Service Centers Bad cable connections Check connectors Electronic box Starter cranks but engine won t start when turning the key in RUN position Bad H T coil connection or coil failure Bad H T coil grounding Check grounding Electronic box or ignition failure Apply to Authorized Service Centers Replace Check status and connection on fuel pipe Replace gaskets and membranes on carburetor Check reed petals Replace if necessary Check stator connector Check Replace Wet spark plug Malfunction on induction system Engine starts but it stops after Bad cable connections few seconds when turning the key in RUN position Electronic box or starter failure Apply to Authorized Service Centers Bad carburetor adjustment Check carburetor adjustment see I screw sect 5 engine is running Centers Rough idle Bad carburetor adjustment Check carburetor adjustment see L screw sect 5 Drop in engine performance Check piston Bad carburetor adjustment Check carburetor adjustement see sect 5 Exhaust too noisy Check and replace if necessary 42 MAN 048 ING 20 ENGINE PRESERVATION When engine is to remain unoperative for long period it must be preserved as follows Disconnect the battery and charge it perio
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