LEOPARD USA MY`09 125cc - RL - TaG
Contents
1. PLACE THE RADIATOR SO THAT THE HOLE ON THE RADIATOR BRACKET AND ONE OF THE UPPER HOLES ON THE BEARING SUPPORT BOX MATCH 1 SCREW M8 SEE FIG 11 ONCE YOU FIND THE CORRECT POSITION TIGHTEN THE M6x25 SCREWS ON THE CLAMP TORQUE 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 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 055A EXHAUST HEADER ASSEMBLY NOTE THE ENGINE IS SUPPLIED WITH THE EXHAUST GASKET AND NUTS ALREADY INSERTED WHEN THE SHIPMENT IS MADE AN EXHAUST CARD BOARD COVER GASKET IS PROVIDED TO PROTECT THE2. 6 89 709 7 28 747 767 786 806 825 844 864 8 83 9 03 33 MAN 055A m OPERATIONS PICTURES DISASSEMBLE THE STARTER UNLOOSE THE SCREW M6 X30 ON THE STARTER SUPPORT See Fig 1 5mm ALLEN WRENCH T TYPE REMOVE THE ADDITIONAL STARTER SUPPORT 3 SCREWS 6 25 See Fig 2 5mm ALLEN WRENCH T TYPE REMOVE THE STARTER SUPPORT 4 SCREWS M6x35 See Fig 3 5mm ALLEN WRENCH T TYPE TO REMOVE THE STARTER UNLOOSE 3 SCREWS M6x35 See Fig 4 5mm ALLEN WRENCH T TYPE EXTRACT STARTER See Fig 5 34 MAN 055A OPENING THE STARTER UNSCREW THE SCREW M4 FIXING THE INPUT CABLE TO THE STARTER see Fig 6 SCREWDRIVER UNSCREW THE 3 SCREWS M5 C See Fig 7 SCREWDRIVER 35 MAN 055A REMOVE DRUM FROM STARTER KEEPING ROTOR IN ITS SEAT BE SURE TO HOLD THE ROTOR ON ITS TOOTHED SIDE TO PREVENT THE BRUSHES FROM FALLING OUT FROM THEIR SEAT see Fig 8 EXTRACT ROTOR FROM THE STARTER HEAD see Fig 9 ZA ATTENTION WHEN EXTRACTING THE ROTOR THE BRUSHES MAY SPRING OUT FROM THEIR SEATS REPLACING THE BRUSH A UNSCREW THE 2 SCREWS M4 D RETAINING THE PLATE see Fig 10 SCREWDRIVER REMOVE THE LITTLE RUBBER CAP F see Fig 11 PLIERS OUR SUGGESTION SLIGHTLY OIL THE TIN PLATE TERMINAL END TO MAKE EASIER THE EXTRACTION OF THE LITTLE RUBBER CAP 36 MAN 055A REMOVE SILICONE FROM BRUSHES WITH A SCREWDRIVE
3. ASSEMBLY INSTRUCTIONS amp USER MANUAL 16 05 2011 MAN 055A INDEX GENERAL DESCRIPTION OF THE ENGINE LEOPARD MY 09 ENGINE CHARACTERISTICS OPERATIONAL LIMITS Contents of packing Engine serial number Preparation and installation of the engine on the chassis 3 1 Installation sketch of the engine on the chassis 3 2 Install the water cooling system 3 3 Exhaust header assembly 3 4 Preparation and installation of the motor mount 3 5 Install the carburettor 3 6 Install the engine on the chassis 3 7 Install the clutch cover with coil 3 8 Electric connections 3 9 Installation of the intake silencer 3 10 Install the exhaust system 4 Gasoline and Oil 5 Carburettor adjustment guide 6 Starting and stopping the engine 7 Engine break in 8 RPM limiter 9 Intake silencer 10 Recommendations on the exhaust system 11 Centrifugal clutch 12 Instructions for the disassembly reassembly of the clutch 13 Battery 14 Warnings on the electrical system 15 Sparkplug and thermal degrees 16 Choice of the best sprocket ratio 17 Replacement of the starter brushes 18 Scheduled maintenance 19 Troubleshooting 20 Engine and accessories preservation 21 Fastener torque table wiring diagram PAGE 23 24 25 25 25 26 27 28 29 30 31 32 35 41 42 43 43 44 GENERAL DESCRIPTION OF THE ENGINE This engine of the TaG series Touch and Go has been expressly designed and developed for the powering of karts for hobby
4. INTERNAL PARTS 3 3 1 REMOVE THE NUTS AND THE EXHAUST CARD BOARD COVER 3 3 2 MAKE SURE THE EXHAUST GASKET IS IN SEAT AND INSTALL THE EXHAUST HEADER SEE FIG 1 3 3 4 INSTALL THE THREE NUTS 12 POINT WRENCH 10 mm OR OPEN WRENCH 10 mm TORQUE AT 9 11 Nm 80 100 in Ib PREPARATION AND INSTALLATION OF THE MOTOR MOUNT NOTE ALL THE DIMENSIONS ARE IN MILLIMETERS 3 4 1 DRILL 4 HOLES DIAM 8 5mm IN THE MOTOR MOUNT 13 5 1 10 MAN 055A 3 4 2 BEFORE INSTALLING THE MOTOR MOUNT POSITION THE ADDITIONAL MOUNT PLATE ON THE CRANKCASE SEE FIG 2 3 4 3 INSTALL THE MOTOR MOUNT MAKE 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 8 TORQUE AT 22 24 Nm 190 210 in Ib 6 mm ALLEN WRENCH INSTALL THE CARBURETTOR 3 5 1 INSTALL THE GAS CABLE CLAMP ON THE SUPPORT SEE FIG 4 12 POINT WRENCH 10mm 11 MAN 055A 3 5 2 REMOVE 2 SCREWS 3 5mm ON THE CARB PUMP IN CORRESPONDENCE OF THE THROTTLE LEVER SEE FIG 5 g SCREWDRIVER 4 8 mm 3 5 3 INSERT THE GAS BRACKET AND THE TWO SCREWS SEE FIG 6 3 5 4 INSTALL THE INTAKE SILENCER SUPPORT 2 SCREWS M5 X10 SEE FIG 7 ALLEN WRENCH 3 mm 3 5 5 INSTALL THE CARBURETTOR SEE FIG 8 9 REMOVE THE TWO M6 NUTS FROM THE INLET MANIFOLD REMOVE THE PLASTIC PLUG FROM THE
5. STARTER WITH THE SCREW M4 see Fig 22 SCREWDRIVER ASSEMBLING THE STARTER PLACE THE STARTER IN SEAT see Fig 23 OIL O RING TO MAKE EASIER INSTALLATION N 3 SCREWS TCH M6x35 TORQUE A 8 10 Nm 70 90 in lb INSTALL THE STARTER ON CRANKCASE N 4 SCREWS M6x35 INSTALL THE ADDITIONAL SUPPORT N3 SCREWS M6X25 AND TORQUE THE SCREW M6X30 ON THE SUPPORT see Fig 23 5mm ALLEN WRENCH T TYPE TORQUE ALL THE SCREWS AT A 8 10 Nm 70 90 in lb 39 MAN 055A 18 SCHEDULED MAINTENANCE Following some simple maintenance standards will allow the engine to perform more reliability and have a longer life SCHEDULE COMPONENTS ACTIONS AND COMMENTS Before using Check alignment with axle sprocket Check status tensioning and oil chain Battery Check status and charge Cables amp connectors Check status and connections and electronic box clamps After use Battery Check status and oil chain External cleaning Every 5 10 hours Bendix assembly Remove cover see fig and clean internally s ZW ju Every 20 hours Piston and con rod Check and replace worn parts assembly Crankshaft Check and replace worn parts Ball bearings Check and replace worn parts 40 MAN 055A 19 TROUBLESHOOTING Below are some common faults their probable causes and suggested remedy FAULTS PROBABLE CAUSES REMEDY Starter will not crank when Bad connections on starter cables Check and tighten turning
6. T O close the screw completely and then open 1 T O Based on various factors as altitude ambient temperature etc it might be necessary to reset the carburettor to optimize the performance of the engine A ATTENTION A Never lean too much as lean mixture will overheat engine and cause seizure Do not force H 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 1 Close by further 1 1 2 T O after contact with throttle lever L Adjust T O from closed to Adjust T O from closed to approximately approximately att T O 1 1 4 Start the engine and warm it If RPM too high adjust L counterclockwise until clutch is disengaged L Continue to turn clockwise is reached Adjust further If RPM If RPM until max R P M is reached Turn c c w until max RPM Adjust c c w fractionally for rich idle Trigger accelerator fractionally for rich idle decreases Increases Trigger accelerator Slowly adjust clockwise Engine is now idling at max attainable RPM or slightly lower on riche side Adjust L counterclockwise until 2000 2500 RPM is reached Recheck L screw for optimum setting required Adjust H until best possible free speed is reached Turn clockwise for higher RPM Counterclockwise for lower RPM Return to idle and check acceleration for adj
7. a ratio 11 92 should be used SPROCKET RATIO TO ACHIEVE MAX 16500 RPM Engine Max Sprocket Ratio RPM during 67 69 711 73175177 61 85 85 87 ag S91 92 tests 13000 825 O1 13200 813 10 8 11 13 11 38 11 6 13400 13600 13000 777 825 849 873 921 945 968 992 11s 10 14000 766 780 813 837 8 60 854 931 955 978 1002 1025 uxo 755 7 79 802 825 8 48 871 8 6 964 988 1011 14400 745 768 751 836 859 842 926 9 28 951 974 i 9 6 E x oo ololo N Oo o O 9 14600 736 757 7 80 862 25 848 670 sss 5 936 9 61 983 umo 7 25 7 69 72 836 ese 881 923 925 948 95 so 7 5 727 759 71 825 847 se 891 923 9 35 957 975 eio N 1 ER 979 15200 7 7 9 01 9 23 9 44 966 98 15400 696 7 18 739 7 6 8 89 15600 688 7 09 7 5 8 78 9 84 15800 679 7 4 8 67 888 9 09 929 950 9 7 16000 7 32 8 56 9 59 8 83 16200 8 45 866 886 906 9 27 947 16400 654 674 694 714 724 756 775 755 815 835 sss 875 sss 96 936 16600 646 666 686 7 06 7 26 745 765 785 805 8 25 9 24 16800 17000 6 31 650 6 70
8. 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 405 410 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 60mm 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 26 MAN 055A 11 CENTRIFUGAL CLUTCH The engine has a low maintenance 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 A ATTENTION Once the engine is started avoid useless accelerations which can overheat and deteriorate the clutch Oil the chain before each test immediately after each race or test check the
9. the engine is stopped with the key in RUN position to restart it turn the key to STOP position and then again to KEY and 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 055A 7 ENGINE BREAK IN cO 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 throttleomaking 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 time 3 Progressively increase the speed of the kart for 5 minutes at 3 4 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 A ATTENTION Once the break in is over and the engine is cold check
10. 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 17 000 RPM This limit cannot be exceeded otherwise the engine could be damaged by the extremely high RPM A 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 carburettor 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 and clean it with gasoline or solvent 25 MAN 055A 10 EXHAUST SYSTEM Before every test make sure that the flexible is not damaged Replace if necessary A 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
11. with 5A fuse Female faston terminal 6 3 O BATTERY 43 MAN 055A 1 dL pole ignition 8 pole female connector SELECOM s gt gt TR Insulating cap Wire terminal with Connector SUMITOMO M4 threaded hole FB 1P M F cs 45 4 female terminal plu Connect to S the H T coil Grounding cable Coil motor
12. 10 Starter ring 3 Roller cage 7 Internal washer 11 Screw 4 Sprocket 8 Locking nut OPERATIONS TOOLS CR BEDS VEU Remove the clutch cover 3 screws M6 Allen wrench 5mm T type 2 Remove seeger ring Pliers cage inner washer 4 Apply the starter ring locking tool and remove the Locking tool S884 M20x1 nut securing the clutch body and starter ring 30 mm socket ZA ATTENTION turn clockwise as nut has left thread 5 Apply clutch puller tool remove body clutch and Clutch puller tool 10272 C gear from crankshaft 12 point wrench 12mm 6 Remove starter ring 3 screws M6 12 point wrench 10 mm 28 MAN 055A Before assembling the clutch wash with diluent the shaft taper the starter ring and clutch drum Clutch assembly 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 Ava TTENTION make sure to always install the O 7 mm dragging pin as otherwise the eventual kick backs could break the screws 2 Install body clutch and starter ring Apply Loctite 641 for coaxial lockings 3 Install clutch body fixing nut and starter gear by Locking tool 5884 means of the starter ring locking tool Allen wrench 30 mm torque at 100 110 Nm 885 975 in Ib ZA ATTENTION turn counterclockwise as nut has left thread 4 Install the
13. 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 5A 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 otherwise 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 15 SPARK PLUG AND THERMAL DEGREE The engine is supplied with a standard NGK BR10EG spark plug which represent
14. AIR 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 055A 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 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 A ATTENTION MAKE SURE THAT THE FIXING TONGUES ARE PROPERLV INSERTED TO GUARANTEE THE BEST POSSIBLE CONNECTION OF THE TERMINALS 3 8 12 DRILL 022mm 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 FUSE HOLDER MAN 055A 3 843 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 CONNECTION OF THE TERMINALS 3 8 14 ATTACH THE DUAL LOCK FIXING STRAP UNDER THE FRONT FAIRING 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
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 055A 3 8 17 PLACE THE WIRING HARNESS BATTERY TERMINALS UNDER THE BATTERY 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 CABLE 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 1752230 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 AND THAT THE HOLES ARE NOT PLUGGED FIX THE FILTER ON THE CARB WITH A STEEL CLAMP AND THE FILTER TO THE CHASSIS SIDE RAILS WITH PLASTIC CLAMPS SEE FIG 39 40 20 MAN 055A INSTALL THE EXHAUST NOTE SEE SECTION 9 FOR THE RECOMMENDATIONS ON THE IDEAL EXHAUST LENGHT 3 11 1 INSTALL THE FLEXIBLE L 60mm FLEXIBLE COMPLETELY CLOSED ON THE EXHAUST HEADER SEE FIG 41 AND ASSEMBLE THE EXHAUST MUFFLER 3 11 2 WIND THE STRAP IN REFRACTOR
16. ING 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 055A INSTALL THE BELTS AND TENSION SEE FIG 4 TIGHTEN THE SCREW M8x45 TORQUE 18 22 Nm 1602190 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 RUBBER DAMPENER HOLES TO FACILITATE INSERTION RADIATOR SUPPORT BRACKET 7 MAN 055A COMPLETE INSERTION OF THE RADIATOR SUPPORT BRACKET INTO THE RUBBER DAMPENERS SEE FIG 7 AND 8 FIX THE RADIATOR SUPPORT BRACKET INSERTING ALSO THE RADIATOR FIXING BRACKET RADIATOR CAP SIDE N SCREW M6x90 AND 1 SCREW 6 85 WITH NUT INSTALL THE L SHAPE BRACKET ON THE LOWER RADIATOR CLAMP AVAILABLE IN DIFFERENT DIAMETERS 28 30 32mm 2 SCREWS M x12 AND FIX IT TO THE TONGUE ON THE RADIATOR SUPPORT BRACKET 1 SCREW 8 20 WITH NUT SEE FIG 9 VITE M6X90 ai RADIAT FIXING BRACKET LOWER FIXING CLAMP MAN 055A PLACE THE RADIATOR FIXING CLAMP ON THE CHASSIS SIDE RAIL BRAKE SIDE N 2 SCREWS M6x25 TIGHTEN THE BOLTS BY HAND SEE FIG 10
17. INLET MANIFOLD 10mm OPEN WRENCH ATTENTION MAKE SURE THAT THE PRESSURE HOLE ON THE GASKET IS NOT PLUGGED 12 MAN 055A x _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 CARBURETTOR N 2 NUTS M6 AND TWO WASHERS TORQUE AT 6 10 Nm 50 90 in Ib BEFORE GOING AHEAD WITH THE OPERATIONS DISASSEMBLE THE CLUTCH COVER WITH H T COIL BY REMOVING THE 3 SCREWS M6x30 ON THE CRANKCASE SEE FIG 10 ALLEN WRENCH 5mm 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 12 3 6 3 INSTALL THE CHAIN PITCH 7 775 SEE FIG 13 13 MAN 055A 3 6 4 MOVE THE ENGINE ON THE RAILS TO OPTIMIZE THE CHAIN TENSION ATTENTION AY OF THE CHAIN MUST BE APPR 16mm 1 2 3 4 inch MEASURED IN THE SHOWN POINT SEE FIG 14 3 6 5 TORQUE THE CLAMP SCREWS 3 7 JINSTALL THE CLUTCH COVER WITH H T COIL 3 7 1 INSTALL THE CLUTCH COVER WITH H T COIL SEE FIG 15 TORQUE THE 3 SCREWS AT 8 10 Nm 70 90 in Ib ALLEN
18. NEL FAIRING SEE FIG 19 TIGHTEN WITH PLASTIC CLAMPS A ATTENTION NEVER LET THE HARNESS GET IN TOUCH WITH THE GROUND OR WITH ROTATING PARTS AS IT COULD BE DAMAGED BEYOND REPAIR 15 MAN 055A 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 Ad ATTENTION MAKE SURE THAT THE FIXING TONGUES ARE PROPERLY INSERTED TO GUARANTEE THE BEST POSSIBLE CONNECTION OF THE TERMINALS 3 8 6 CHECK THE ELECTRIC STARTER FIXING SEE FIG 22 FIX THE HARNESS EYELET GROUND CABLE WITH THE EYELET TERMINAL TO THE STARTER SUPPORT BY MEANS OF THE FIXING SCREW M6x35 SEE FIG 23 ALLEN SCREW 5 mm TORQUE AT 10 Nm 70 90 in lb A ATTENTION THIS OPERATION IS EXTREMELV IMPORTANT AS AN UNCERTAIN GROUNDING COULD DAMAGE THE ELECTRONIC BOX BEVOND REPAIR 16 MAN 055A 3 87 COMPLETE THE FIXATION OF THE HARNESS SEE FIG 24 A ATTENTION NEVER LET THE HARNESS GET IN TOUCH WITH THE GROUND OR WITH A ROTATING PART AS IT COULD BE DAMAGED BEYOND REPAIR 3 88 FIX THE SECOND HARNESS GROUND CABLE WITH THE EVELET TERMINAL 6 5mm TO THE H T COIL BY MEANS OF THE M6 NUT SEE FIG 25 ALLEN SCREW 5mm TORQUE AT 8 10 Nm 70 90 in Ib ATTENTION THIS OPERATION IS EXTREMELY IMPORTANT AS AN UNCERTAIN GROUNDING COULD DAMAGE THE ELECTRONIC BOX BEYOND REP
19. R see Fig 11 REMOVE SPRINGS MAKING PRESSURE EXTERNALLY ON THE TIN PLATE TERMINAL REMOVE BRUSH See Fig 13 INSTALL NEW BRUSH TERMINAL See Fig 14 PLACE THE LITTLE RUBBER CAP ON THE TERMINAL REINSTALL THE PLATE AND FIX IT WITH HE 2 SCREWS M4 See Fig 15 SCREWDRIVER 3 MAN 055A REPLACEMENT OF THE BRUSH B UNLOOSE RHE SCREW M3 G See Fig 16 EXTRACT THE BRUSH FIX THE NEW BRUSH WITH SCREW M6 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 HOCK REPEAT THE SAME PROCEDURE TO INSTALL THE BRUSH B See Fig 17 INSTALL THE ROTOR BETWEEN THE IE BRUSHES AND CHECK THAT THEY ARE ALWAYS IN CONTACT WITH THE CYLINDRIC COPPER PART OF THE ROTOR EVEN WHEN THEY ARE RELEASED See Fig 18 M lli ll OUR SUGGESTION TO IMPROVE THE BRUSHES LIFE SECURE THE LITTLE WIRES WITH SILICONE See Fig 19 38 MAN 055A CHECK THAT O RING H IS 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 20 TORQUETHE 3 SCREWS M5 see Fig 21 SCREWDRIVER CHECK THAT THE STARTER ROTOR ROTATES FREELY CONNECT THE INPUT WIRING TO THE
20. WRENCH 5 mm ATTENTION ALWAYS MAKE SURE THAT THE GROUND CABLE ALWAYS CONNECTS THE COIL WITH THE ENGINE AN INADEQUATE GROUNDING COULD DAMAGE THE IGNITION BEYOND 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 BEYOND REPAIR 14 MAN 055A 3 8 ELECTRICAL CONNECTIONS refer to the attached electrical schematic NOTE FOR A PROPER INSTALLATION FOLLOW THE UNDER SHOWN INSTRUCTIONS 3 8 1 INSERT THE BATTERY STRAP IN THE BATTERY SUPPORT SEE FIG 16 3 8 2 PLACE THE BATTERY SUPPORT BOX IN THE FRONT OF THE CHASSIS UNDER THE FRONT FAIRING AND FIX IT WITH THE CLAMPS TO THE LOWER STEERING COLUMN SUPPORT TUBES M6x25 SCREWS SEE FIG 17 1Omm SOCKET WRENCH 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 THE 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 A ATTENTION PAY ATTENTION NOT TO SHORT CIRCUIT THE BATTERY 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 PA
21. Y MATERIAL ROUND THE FLEXIBLE AND FIX IT WITH THE 3 SPRINGS SEE FIG 42 TS L mn DE Unies e wyw UM THE ENGINE IS READY TO BE STARTED 21 MAN 055A 4 GASOLINE and OIL Use leaded or unleaded Premium Gasoline 92 RON MON mixed with oil at 696 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 carburettor 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 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 055A 5 CARBURETTOR ADJUSTMENT GUIDE 1 THROTTLE v HIGH SPEED FUEL MIXTURE SCREW SPEED SCREW L LOW SPEED FUEL MIXTURE SCREW 1 1 2 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 1 2
22. atio Teeth n axle 10 11 Teeth n axle 10 sprocket sprocket ma 8 Sprocket Teeth n Engine sprocket Teeth n Engine sprocket 790 90 80 72 810 7386 ma so 7 32 MAN 055A 75 75 682 8 72 73 74 75 76 77 78 79 81 82 For the operaton limit of 16 500 RPM the following table N 2 has been prepared SUGGESTION u During the track tests we recommend use of a tachometer recording the max obtained engine RPM u Use sparkplug caps with a resistance of 5 to avoid eventual interferences between the engine ignition and the tachometer and or telemetry 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 u Make a few laps on the track and let us assume that you read 14 000 max engine RPM u From the table 2 to achieve a max RPM of 16 500 RPM operating limit for the Leopard MY 09 engine a 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
23. e Cooling Water e Ignition Digital with integral rev limiter Battery charge With integral generator e Electric start 12V 0 30 Kw e Clutch Automatic dry centrifugal Operational limits e Max RPM 17 000 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 125 MY 09 engine is supplied with the under shown accessories e Flexible H T coil otarting key assembly Quantity 22 x MAN 055A ACCESSORIES CLUTCH COVER COIL COMPLETE ELECTRIC ASSEMBLY INTAKE SILENCER COMPLETE PUMP GROUP WATER HOSE KIT RADIATOR 3 MAN 055A 2 MOTOR IDENTIFICATION NUMBER The official motor identification number can be found stamped in the front right part of the crankcase next to the electric starter see fig The number 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 processes and do not identify the motor NOTE In case of need for spares and when contacting the AME Support Centers please always refer to the Motor Identification Number and to the motor model 4 MAN 055A 3 PREPARATION AND INSTALLATION OF THE ENGINE ON THE CHASSIS NOTE In cas
24. e 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 5 MAN 055A 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 32 ASSEMBLE THE PUMP FIXING BRACKET 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 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 ALIGN
25. 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 6 000 RPM Every time 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 When 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 A 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 2 MAN 055A 12 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 1 Seeger ring 5 Clutch drum 9 Clutch body 2 Washer 6 Screw
26. he power pack An RPM limiter integrated in the power pack prevents the engine from exceeding 17 000 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 carburettor is a diaphragm Tillotson carburettor Tillotson HL series 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 055A CHARACTERISTICS OF THE LEOPARD ENGINE OPERATIONAL LIMITS The characteristics of the engine are the following e Cycle 2 stroke e Original cubic capacity 123 67 cc e Original 54 00 mm Max theoretical bore 54 28 mm e Stroke 54 00 mm e Lubrification Fuel oil mix 6 16 1 e Induction Heed valve e Carburettor Membrane Tillotson
27. his 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 to 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 fix correctly 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 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 30 MAN 055A 9 The digital assembly needs use of a resistive spark plug cap or spark plug The resistor value must be equal or higher than
28. internal washer A ATTENTION install washer with bevel towards internal part of the engine Clean the roller cage and grease it before installing it on the crankshaft 5 Install the clutch drum and external washer 5mm Allen wrench T 7 Re assemble the clutch cover 3 screws M 6 torque 8 10 Nm 70 90 in Ib 13 BATTERY The battery 12 V 9 Ah is sealed and without maintenance In order to lenghten the battery life it is necessary though to follow a few recommendations u When the tension drops below 12 6V it is necessary to recharge the battery Max allowed recharging current is 1 8A u The 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 C 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 s 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 055A A ATTENTION Always connect the negative terminal before and the positive terminal after Always disconnect the battery in opposite o
29. lack symptoms listed aside shadv soot Ignition difficulties ATTENTION Note a wet or oily electrode could also mean Always use a colder than standard sparkplug an excessively rich mixture with hot climates MAN 055A COMPARISON TABLE BASED ON THE THERMAL DEGREE HOT OCS 1 BRIEG 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 etc 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 MY 09 engine is 17 000 RPM and the RPM limiter is calibrated at this value A ATTENTION Never exceed the above limit No obligation of exists in case the above limit is exceeded 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 Tab 1 Sprocket r
30. ne is to remain unoperative for a long period it must be preserved as follows Disconnect the battery and charge it periodically see Sect 12 Disconnect carburettor 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 E Q TY FASTENER NAME WRENCH VALUES Nm VALUES in i M14 x 1 25 1 Spark plug Hex 20 8 20 26 175 230 4 Head and cylinder nut 18 22 160 190 Exhaust nut TI Reed group screw Carb fixing stud bolt Air filter screw Coil attach screw Ignition cover screw Allen Ign Digit K stator fixing screw Allen Ign Digit K rotor fixing nut Hex Bendix support screw Allen 5 Starter support fixing screw Allen 5 2 Starter ring fixing nut Hex 20 100 770 685 870 Clutch fixing screw 20 8 TU 80 700 Add starter supp fix screw Allen 5 70 Sg Additional supp locking screw Allen 5 SU CN CA 4 2 4 2 2 J 4 3 42 MAN 055A Electronic unit wilh micro 20 pole connector SELECOM 4 pole female connector pole male connector M c 8 pole male connector SELECOM pole female connector SELECOM Starter key assembly Fuse holder
31. 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 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 SSH protected from short circuits supplies the power for the electric starter and is controlled by t
32. rder Recharge the battery at least once every 6 months Never let the battery tension dropping under 8V as whenever it drops under this limit the battery cannot be used any longer and it has to be replaced 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 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 AN ATTENTION If these prescriptions are not followed the electrical system and the engine could be damaged beyond repair No obligation of IAME exists in t
33. s 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 mixtures can generate the same final look which can also be achieved with a hot or cold spark plug oee table An excessively warm spark plug shows the Extremely clear color porous look and svmptoms listed aside calcification of the electrodes and of the internal insulation ATTENTION Irregularities in the ignition preignition and Alwavs use a warmer than standard spark plug detonation with tendencv to perforate the top of with cold or rainv climates the piston Note Some of these svmptoms 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 An excessively cold spark plug shows the Insulator end and electrodes covered with b
34. the key to RUN position Bad grounding Check connections and tighten Interruption on fuse Replace 5A strip fuse after checking for eventual reversal of battery polarity Damaged cables Replace Batterv connections loose Check and tighten Recharge batterv or replace Overhaul starter Applv to Authorized Service Center Starter cranks but engine won t Bad connections on cables Check connectors start when turning the key in RUN position Bad coil connection or coil Check Replace failure Bad H T coil grounding Check grounding Electronic box or ignition failure Apply to Authorized Service Center Wet spark plug Replace Malfunction on induction svstem Check status and connection on fuel pipe Replace gaskets and membranes on carburettor Check reed petals Replace if necessary Engine starts but it stops after a Bad cable connections Check stator connector few seconds when turning the key in RUN position Electronic box or ignition failure Apply to Authorized Service Center Check carburettor adjustment see L screw sect 5 engine is running screw l sect 5 Drop in engine performance Check piston Bad carburettor adjustment Check carburettor adjustment see sect 5 Check and clean Exhaust too noisy Flexible damaged Check and replace if necessary Springs damaged or lost Insulating strap damaged Damaged exhaust header 41 MAN 055A 20 ENGINE PRESERVATION When engi
35. ust 8 by acceleration quick response and smooth pick up Acceleration Engine is ready to operate 23 MAN 055A 6 STARTING AND STOPPING THE ENGINE otarting is achieved by the starting key This is a 3 position key 1 STOP key can be removed 2 KEY 3 RUN 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 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 connects the battery B Turn the key to RUN position to 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 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
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