IAME Leopard Owners Manual
Contents
1. Max water Temperature 90 c ATTENTION Never exceed the above limits no obligation of IAME exists in case the above limits are exceeded MAN 016 D 2 1 CONTENT OF THE PACKING Each Leopard engine is delivered with the under shown accessories 125 cc LEOPARD TaG engine EXHAUST Flexible 1 Spring For Flexible 3 Exhaust Fiber Strip 1 Exhaut Header 1 Exhaust Muffler 1 INDUCTION Tillotson Carburetor 1 Intake Silencer 1 Intake Silencer Support 1 Accelerator Cable Bracket 1 ELECTRICAL Battery 12 V 1 Battery Support 1 Battery Strap 1 Battery Clamps 2 Power Pack Box with Harness 1 Plastic Fixing Clamps 8 NGK BR 10 EG Spark Plug 1 Spark Plug Cap 1 MISCELLANEOUS Additional Engine Plate 1 Additional starter support 1 Water proof cover 1 Clutch cover with H T coil 1 WATER COOLING Radiator 1 Radiator Support Kit 1 Complete Hose Kit 1 Pump complete 1 MAN 016 D 3 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 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 m2. by pushing the green start button 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 7 2Ah is a sealed no maintenance battery and is supplied already preassembled in the Power Pack 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 MAN 016 D 1 CHARACTERISTICS OF THE LEOPARD ENGINE OPERATIONAL LIMITS 1 The characteristics of the engine are the following Cycle OTTO 2 stroke Original cubic capacity 123 7 cc Original bore 54 00 mm Max theoretical bore 54 28 mm Stroke 54 00 mm Lubrication Fuel Oil mix Induction Reed valve Carburetor Membrane Tillotson Cooling water Ignition Digital 4 poles with internal rotor Battery charge With integral generator Electric start 12V 0 30 Kw Clutch Automatic dry centrifugal 2 OPERATIONAL LIMITS Max RPM 15000 RPM Min waterTemperature 45 c
3. 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 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 MAN 016 D 21 5 CARBURETOR ADJUSTMENT GUIDE I THROTTLE SPEED SCREW 1 T O L LOW SPEED FUEL MIXTURE H HIGH SPEED FUEL MIXTURE RICH LEAN 1 T O T O 1 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 T O H close the screw completely and then open 1 1 T O 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 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 H Adjust T O from closed to approximately 1 T O L Adjust T O from closed to approximately
4. MAN 016 D 125cc LEOPARD TaG engine ASSEMBLY INSTRUCTIONS and USER MANUAL INDEX GENERAL DESCRIPTION OF THE LEOPARD ENGINE Page CHARACTERISTICS OF THE LEOPARD ENGINE OPERATIONAL LIMITS 1 Contents of the packing 2 Motor identification Number 3 Preparation and installation of the engine on the chassis 3 1 Install the water cooling system 3 2 Exhaust header assembly 3 3 Preparation and installation of the motor mount 3 4 Install the carburetor 3 5 Install the engine on the chassis 3 6 Install the clutch cover with H T coil 3 7 Installation and connection of the power pack box 3 8 Electrical connections on the engine 3 9 Installation of the intake silencer 3 10 Install the exhaust 4 GASOLINE and OIL 5 Carburetor Adjustment guide 6 Starting and stopping the engine 7 Engine break in 8 Inlet silencer 9 Exhaust system 10 Centrifugal clutch 11 Instructions for the assembly disassembly of the clutch 12 Battery 13 Spark plug and thermal degree 14 Choice of the best sprocket ratio 15 Scheduled maintenance 16 Troubleshooting 17 Engine and accessories preservation Attachments Fastener Torque Table Wiring diagram MAN 016 D 1 1 2 3 4 5 5 9 9 10 12 13 14 16 19 20 21 22 23 23 23 24 24 26 27 28 29 32 33 34 35 36 GENERAL DESCRIPTION OF THE LEOPARD ENGINE This engine of the TaG series Touch and Go has been expressly designed and develop
5. 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 5mm per time 10 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 MAN 016 D 24 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 If the kart dragging speed exceeds 6000 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 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 mater
6. 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 and clean it with gasoline or solvent MAN 016 D 23 9 EXHAUST SYSTEM Before every test make sure that the flexible is not damaged Replace if necessary ATTENTION In case the flexible is damaged metallic particles could be sucked in the engine and cause a seizure Always make sure that the springs are well hooked and in place In case of breakage replace the broken spring 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
7. at 8 10 Nm 70 90 in lb 12 BATTERY The battery 12 V 7 2 Ah included in the supply is sealed and without maintenance In order to lengthen the battery life it is necessary though to follow a few recommendations When the tension drops below 12 6V it is necessary to recharge the battery Max allowed recharging current is 1 8A 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 extremely quick charge with excessive current could damage the battery the battery would tend to swell Choose a battery charger with the following characteristics 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 1 max per day Fully recharge battery before use MAN 016 D 27 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 recommend
8. 1 T O I Close by further 1 T O after contact with throttle lever Start the engine and warm it If R P M too high adjust I counterclockwise until clutch is disengaged Turn c c w until max R P M is reached Adjust further fractionally for rich idle Trigger accelerator If R P M decreases L Slowly adjust clockwise If R P M increases Continue to turn clockwise until max R P M is reached Adjust c c w fractionally for rich idle 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 Adjust L slightly richer by 1 8 T O Bad acceleration Return to idle and check acceleration for quick response and smooth pick up Good acceleration Engine ready to operate MAN 016 D 22 6 STARTING AND STOPPING THE ENGINE Press the green button on the Power Pack If the engine can t be started within 5 seconds check that gas gets to the carb interrupt and try again after 15 seconds Shorts and frequent tries are better than long ones In case the engine can t be started refer to Par 16 Troubleshooting The engine can be stopped by pressing the red button on the Power Pack B
9. Clutch puller P N B 55614 C 19mm socket 7 Remove key from shaft 8 Remove the starter ring 3 screws M6 10 mm socket MAN 016 D 26 Before assemblying the clutch wash with diluent the shaft taper the connecting hole on the clutch body the clutch drum and the starter ring Clutch assembly 1 Install the starter ring on the clutch body by matching the 3 holes and the dragging pin 3 screws M6 ATTENTION make sure to always install the 7 mm dragging pin as otherwise the eventual kick backs could break the screws 10 mm socket Torque at 10 Nm 90 in lb Apply Loctite on the threads 2 Insert key on shaft 3 Install clutch body and the cone safety washer 4 Install the 16 x 1 nut using the clutch wrench ATTENTION turn counterclockwise as nut has left thread Clutch wrench P N 10270 24 mm socket Torque at 40 50 Nm 350 440 in lb 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 turning and install the 10 mm nut Piston fitting P N 10271 17 mm socket Torque at 30 40 Nm 265 350 in lb 8 Install the clutch cover 3 screws M 6 Allen 5 mm Torque
10. E INTERNAL WIRE SEE FIG 33 3 8 7 INSERT THE SPARK PLUG CAP ON THE SPRING SEE FIG 34 INSTALL THE SPARK PLUG AND THE CAP OVER THE SPARK PLUG INSTALL THE SPARK PLUG INSTALL THE SPARK PLUG CAP MAKING SURE THAT THE SPRING IN THE CAP IS WELL INSERTED IN THE SPARK PLUG 3 9 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 CLAMPS SEE FIG 35 36 Fig 33 Fig 34 Fig 35 Fig 36 MAN 016 D 19 3 10 INSTALL THE EXHAUST SEE SECTION 9 FOR RECOMMENDATIONS ON THE IDEAL LENGHT OF THE EXHAUST 3 10 1 INSTALL THE FLEXIBLE L 65mm FLEXIBLE COMPLETELY CLOSED AND THE EXHAUST HEADER SEE FIG 37 AND CONNECT THE EXHAUST 3 10 2 INSTALL THE FIBER STRIP AROUND THE FLEXIBLE AND FIX WITH THE 3 SPRINGS SEE FIG 38 Fig 37 Fig 38 THE ENGINE IS READY TO BE STARTED MAN 016 D 20 4 GASOLINE and OIL Use leaded or unleaded Premium Gasoline 92 RON MON mixed with oil at 6 16 1 Use oils containing Castor Oil which guarantees an optimized lubrication at high temperatures 2 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
11. ENTION AN INADEQUATE GROUNDING OF THE POWER PACK BOX COULD DAMAGE THE BOX BEYOND REPAIR MAKE SURE TO CAREFULLY FOLLOW THE UNDER SHOWN INSTRUCTIONS 3 7 6 1 REMOVE THE SCREW FROM THE SEAT SUPPORT LOCATED UNDERNEATH THE SEAT IN CASE THE POWER PACK BOX IS POSITIONED TOWARDS THE FRONT OF THE CHASSIS OR ON THE SIDE OF THE SEAT IN CASE THE POWER PACK BOX IS POSITIONED TOWARDS THE REAR OF THE CHASSIS Fig 19 Fig 20 Fig 21 MAN 016 D 15 3 7 6 2 FILE THE PAINTING ON THE SEAT SUPPORT UP TO BARE METAL SEE FIG 22 ATTENTION THIS OPERATION IS EXTREMELY IMPORTANT AS AN UNCERTAIN GROUNDING COULD DAMAGE THE POWER PACK BOX BEYOND REPAIR 3 7 6 3 INSERT THE BOX GROUND CABLE EYELET ON THE SCREW AND TIGHTEN THE SCREW SEE FIG 23 3 7 7 POSITION THE HARNESS FROM THE POWER PACK BOX ALONG THE CENTRAL RAIL UNDERNEATH THE SEAT AND TIGHTEN WITH PLASTIC CLAMPS SEE FIG 24 ATTENTION NEVER LET THE HARNESS GET IN TOUCH WITH THE GROUND OR WITH ROTATING PARTS AS IT COULD BE DAMAGED BEYOND REPAIR 3 8 ELECTRICAL CONNECTIONS ON THE ENGINE 3 8 1 CONNECT THE TERMINALS 3 AND 4 WAYS ON THE HARNESS FROM THE POWER PACK BOX WITH THE TERMINALS ON THE CABLES FROM THE IGNITION SEE FIG 25 26 ATTENTION MAKE SURE THAT THE FIXING TONGUES ARE PROPERLY INSERTED TO GUARANTEE THE BEST POSSIBLE CONNECTION OF THE TERMINALS Fig 23 Fig 22 Fig 24 Fig 25 MAN 016 D 16 3 8 2 CONNECT T
12. GINE WON T START INSTALL THE CARBURETOR N 2 NUTS M6 AND TWO WASHERS TORQUE AT 6 10 Nm 50 90 in lb 3 5 INSTALL THE ENGINE ON THE CHASSIS 3 5 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 5 2 CHECK THE ALIGNMENT OF THE ENGINE SPROCKET AND THE AXLE SPROCKET WITH A STRAIGHT EDGE SEE FIG 11 3 5 3 INSTALL THE CHAIN PITCH 219 SEE FIG 12 Fig 9 Fig 10 Fig 11 Fig 12 MAN 016 D 12 3 5 4 MOVE THE ENGINE ON THE RAILS AND OPTIMIZE THE CHAIN TENSION ATTENTION THE PLAY OF THE CHAIN MUST BE APPR 15mm inch MEASURED IN THE SHOWN POINT SEE FIG 16 3 5 5 TORQUE THE CLAMP SCREWS INSTALL THE CLUTCH COVER WITH H T COIL 3 6 3 6 1 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 lb 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 5mm ALLEN Fig 13 15mm Fig 14 Fig 15 MAN 016 D 13 ELECTRICAL CONNECTION re
13. HE CABLE RED FROM THE POWER PACK BOX TO THE ELECTRIC STARTER USE THE SCREW ALREADY INSTALLED ON THE CABLE SEE FIG 27 3 8 3 FIX THE ELECTRIC STARTER AND THE CABLE SEE FIG 28 AND COMPLETE THE FIXING OF THE HARNESS SEE FIG 29 ATTENTION NEVER LET THE HARNESS GET IN TOUCH WITH THE GROUND OR WITH A ROTATING PART AS IT COULD BE DAMAGED BEYOND REPAIR Fig 26 Fig 29 Fig 28 Fig 27 MAN 016 D 17 3 8 4 CONNECT THE COIL CABLE FROM THE POWER PACK TO THE TERMINAL ON THE COIL SEE FIG 30 SUGGESTION SEAL THE TERMINAL ON THE COIL WITH PLASTIC TAPE TO AVOID THAT EVENTUAL VIBRATIONS MIGHT DISCONNECT THE TERMINAL 3 8 5 GROUND THE ENGINE ATTENTION AN INADEQUATE GROUNDING OF THE ENGINE COULD DAMAGE THE IGNITION BEYOND REPAIR MAKE SURE TO CAREFULLY FOLLOW THE UNDER SHOWN INSTRUCTIONS 3 8 5 1 REMOVE THE SIDE BUMPER ON THE CHASSIS ENGINE SIDE IF NOT REMOVED YET 3 8 5 2 FILE THE PAINTING ON THE SLEEVE TO BARE METAL SEE FIG 31 ATTENTION THIS OPERATION IS EXTREMELY MPORTANT AS AN UNCERTAIN GROUNDING COULD DAMAGE THE IGNITION BEYOND REPAIR 3 8 5 3 INSTALL THE SIDE PLASTIC BODY AND CONNECT THE GROUND CABLE FROM THE CLUTCH COVER TO THE CHASSIS BY TIGHTENING THE FIXING SCREW SEE FIG 32 Fig 30 Fig 31 Fig 32 MAN 016 D 18 3 8 6 PUNCTURE THE INSULATING MATERIAL ON THE H T CABLE WITH THE END OF THE CAP SPRING SO THAT THE SPRING IS IN SURE CONTACT WITH TH
14. NG ITS RACES WITH THE DRIVEN PULLEY TIGHTEN THE CLAMPS WITH TWO SCREWS M6 X 25 Fig 1 Fig 2 Fig 3 MAN 016 D 5 4 INSTALL THE BELTS AND TENSION SEE FIG 4 BEFORE INSTALLING THE RADIATOR PREASSEMBLE THE FOLLOWING COMPONENTS 5 ASSEMBLE THE CONNECTING BRACKET ON THE RADIATOR SUPPORT BRACKET 6 INSTALL THE UPPER LEFT BRACKET ON THE CONNECTING BRACKET SEE FIG 5 7 INSERT THE RADIATOR BY FITTING IT ON THE SUPPORTS SEE FIG 6 Fig 4 Fig 5 RADIATOR SUPPORT BRACKET CONNECTING BRACKET UPPER LEFT BRACKET Fig 6 MAN 016 D 6 8 INSTALL THE UPPER RIGHT BRACKET AND FIX TO THE RADIATOR FIXING SUPPPORT TORQUE ALL BOLTS 9 PLACE THE RADIATOR SUPPORT BRACKET ON THE SIDE RAIL BRAKE SIDE TIGHTEN THE BOLTS BY HAND SEE FIG 8 10 PLACE THE RADIATOR SO THAT THE HOLE ON THE RADIATOR FIXING SUPPORT AND ONE OF THE UPPER HOLES OF THE BEARING SUPPORT BOX MATCH ONCE YOU FIND THE CORRECT POSITION FIX THE WHOLE 11 THE KIT INCLUDES TWO RUBBER HOSES CONNECT THE FIRST HOSE TO THE FITTING ON THE RADIATOR INLET AND THE FITTING ON THE ENGINE OUTLET TIGHTEN WITH STEEL CLAMPS SEE FIG 10 Fig 7 RADIATOR FIXING SUPPORT UPPER RIGHT BRACKET Fig 8 Fig 9 MAN 016 D 7 12 CUT THE SECOND HOSE AT AN APPROPRIATE LENGHT TO CONNECT ON ONE SIDE THE FITTINGS ON THE RADIATOR OUTLET AND THE PUMP INLET AND ON THE OTHER SIDE THE FITTINGS ON THE PUMP OUTLET AND THE ENGINE I
15. NLET SEE FIG 10 FIX WITH STEEL CLAMPS Fig 10 BEFORE STARTING THE ENGINE FOLLOW THESE RECOMMENDATIONS Unscrew the cap on the radiator and loosen the breather plug on the engine head 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 lt 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 MAN 016 D 8 3 2 EXHAUST HEADER ASSEMBLY NOTE THE ENGINE IS SUPPLIED WITH THE EXHAUST GASKET AND NUTS ALREADY INSERTED WHEN THE SHIPMENT IS MADE AN EXHAUST COVER TO PROTECT THE INTERNAL PARTS 3 2 1 REMOVE THE NUTS AND THE EXHAUST COVER 3 2 2 MAKE SURE THE EXHAUST GASKET IS SEATED AND INSTALL THE EXHAUST HEADER SEE FIG 1 3 2 3 INSTALL THE WASHERS SUGGESTION PUT THE ENGINE IN HORIZONTAL POSITION AND SET INTO POSITION THE WASHERS WITH A SCREWDRIVER 3 2 4 INSTALL THE THREE NUTS TORQUE AT 9 11 Nm 80 100 in lb 10 mm SOCKET WRENCH OR 10 mm OPEN WRENCH PREPARATION AND INSTALLATION OF THE MOTOR MOUNT NOTE ALL DIMENSIONS ARE IN MILLIMETERS 3 3 3 3 1 DRILL 4 HOLES DIAM 8 5mm IN THE MOTOR MOUNT AND THE STARTER SUPPORT Fig 1 MAN 016 D 9 3 3 2 BEFORE INSTALLING THE MOTOR M
16. OUNT POSITION THE ADDITIONAL MOUNT PLATE ON THE CRANKCASE SEE FIG 2 AND MAKE SURE THAT THE RUBBER RING IN THE SUPPORT IS INSERTED ON THE STARTER BODY 3 3 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 19mm THE SCREW MUST PROTRUDE FROM THE PLATE FOR 16 19mm SEE FIG 3 AND DRAW PAG 9 4 ALLEN SCREWS M8 TORQUE AT 22 24 Nm 190 210 in lb 6 mm ALLEN WRENCH INSTALL THE CARBURETOR 3 4 3 4 1 INSTALL THE GAS CABLE CLAMP ON THE SUPPORT SEE FIG 4 12 POINT WRENCH 10mm Fig 2 Fig 3 Fig 4 MAN 016 D 10 3 4 2 REMOVE 2 SCREWS 3 5mm ON THE CARB PUMP IN CORRESPONDENCE OF THE THROTTLE LEVER SEE FIG 5 SCREWDRIVER 4 8 mm 3 4 3 INSERT THE GAS BRACKET AND THE TWO SCREWS SEE FIG 6 3 4 4 INSTALL THE INTAKE SUPPORT 2 SCREWS M5 X10 SEE FIG 7 3 mm ALLEN WRENCH 3 4 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 10MM OPEN WRENCH Fig 5 Fig 6 Fig 7 Fig 8 MAN 016 D 11 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 EN
17. 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 engine is 15000 RPM ATTENTION Never exceed the above limits No obligation of IAME exists in case the above limits are 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 219 Table 1 shows the various ratios between the sprocket on the axle and the engine sprocket given the different axle sprockets MAN 016 D 29 Sprocket ratio Teeth n Engine sprocket Sprocket ratio Teeth n Engine sprocket Teeth n axle sprocket 10 11 Teeth n axle sprocket 10 11 72 7 20 6 55 83 7 55 73 7 30 6 64 84 8 40 7 64 74 7 40 6 73 85 8 50 7 73 75 7 50 6 82 86 8 60 7 82 76 7 60 6 91 87 8 70 7 91 77 7 70 7 00 88 8 80 8 00 78 7 80 7 09 89 8 90 8 09 79 7 90 7 18 90 9 00 8 18 80 8 00 7 27 91 9 10 8 27 81 8 10 7 36 92 9 20 8 36 82 8 20 7 45 Tab 1 8 30 For the operation limit of 15000 RPM the following table Tab 2 has been prepared SUGGESTION Duri
18. anufacturing 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 MAN 016 D 4 3 PREPARATION AND INSTALLATION OF THE ENGINE ON THE CHASSIS NOTE In case the engine is supplied already assembled on the chassis it is at care of the assembler to follow these instructions The final customer in this case can skip this section and can start reading from section 4 Whenever the engine or a component is disassembled it is necessary to always follow the under shown instructions for proper reassembly 3 1 INSTALL THE WATER COOLING SYSTEM NOTE To install the water pump belts it is necessary to remove the rear axle 1 REINSTALL THE REAR AXLE AFTER HAVING INSERTED THE TWO BELTS SUGGESTION INSTALL OTHER TWO BELTS AS SPARES AND FIX THEM WITH TAPE TO THE AXLE 2 INSTALL THE WATER PUMP 1 SCREW M6 X 45 WITH WASHER AND SELF LOCKING NUT ON THE PUMP BRACKET ON THE REAR CROSS RAIL SEE FIG 1 IN CASE THERE IS NO BRACKET FOR THIS PURPOSE IT I S NECESSARY TO INSTALL THE PUMP ON REMOVABLE CLAMPS AVAILABLE IN DIFFERENT DIAMETERS 28 30 32mm AS ACCESSORIES SEE FIG 2 TIGHTEN BY HAND THE SCREW ON THE PUMP LETTING IT FREE TO ROTATE FOR THE TENSIONING OF THE BELTS 3 INSTALL ON THE AXLE THE DRIVING PULLEY n 2 CLAMPS AVAILABLE IN DIFFERENT DIAMETERS 30 35 40 50mm ALIGNI
19. ations Pay attention not to have free fires upon or around the battery Never shortcircuit 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 clotches 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 13 SPARKPLUG AND THERMAL DEGREE The engine is supplied with a standard NGK BR10EG sparkplug which represents a good compromise between the needs of a good break in and the racing needs in normal conditions Use of different sparkplugs is possible and as a general information we are attaching a correspondence list among sparkplugs of other brands based on thermal degree which represents the capacity of the sparkplug to dissipate the internal heat The colour of the various parts of the sparkplug 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
20. ck 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 and Power Pack Check status and connections Engine mount and clamps Check torques After use Battery Disconnect Chain Check status and oil chain Engine External cleaning Bendix assembly Remove cover see fig and clean internally Every 5 10 hours Exhaust muffler Remove muffler end clean Inlet silencer Open clean Engine head Open clean Engine clutch Open check status of parts every 20 hours Piston and Con rod assembly Check and replace worn parts Crankshaft Check and replace worn parts Ball bearings Check and replace worn parts MAN 016 D 32 16 TROUBLESHOOTING Below are some common faults their probable causes and suggested remedy FAULTS PROBABLE CAUSE REMEDY Starter will not crank when pushing the start button Bad connections on starter cables Check and tighten Bad grounding Check connections and tighten Damaged cables Replace Battery connection loose Check and tighten Battery discharged Recharge battery Starter failure Overhaul starter Power Pack internal failure fuse starter relay connectors Apply to Authorized Service Center Starter cranks but engine won t start Bad cable connections Check connectors 3 and 4 ways Bad H T coil connec
21. ed 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 igniton includes a 4 pole stator rotor with integral pick up an H T coil and an electronic unit with micro processor Power Pack complete with wiring harness The main features of the ignition are During the start of the engine the power pack activates a booster which increases the spark energy to facilitate the starting of the engine The ignition system permits through the electronic unit the onboard battery recharging during the normal use of the engine 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 The engine has an integrated electric starter
22. fer to the attached electrical schematic 3 7 INSTALLATION AND CONNECTION OF THE POWER PACK BOX NOTE THE POWER PACK BOX IS SUPPLIED ALREADY ASSEMBLED ON THE BATTERY SUPPORT WITH BATTERY FOR A CORRECT INSTALLATION FOLLOW THE UNDER SHOWN INSTRUCTIONS 3 7 1 EXTRACT THE BATTERY FROM THE SUPPORT AFTER HAVING UNLACED THE BATTERY STRAP SEE FIG 16 3 7 2 POSITION THE SUPPORT CLAMPS ON THE OUTSIDE RAIL BRAKE SIDE AT THE HEIGHT OF THE SEAT NOTE DIFFERENT CLAMPS ARE AVAILABLE DEPENDING ON THE DIAMETER OF THE TUBE ON THE CHASSIS FIX THE CLAMPS BY HAND WITH 2 SCREWS M6 X 25 SEE FIG 17 3 7 3 POSITION THE BATTERY SUPPORT BOX ON THE CLAMPS MATCHING THE ATTACHMENT HOLES SEE FIG 18 FIX THE BOX WITH TWO SCREWS M6 X 10 MOVE THE BOX WITH THE 2 CLAMPS TO THE MOST SUITABLE POSITION TORQUE THE M6 SCREWS AT 8 10 Nm 70 90 in lb TWELVE POINT WRENCH 10mm Fig 16 Fig 17 Fig 18 MAN 016 D 14 3 7 4 INSERT THE BATTERY STRAP SEE FIG 19 3 7 5 INSERT THE BATTERY WITH TERMINALS TOWARDS THE OUTSIDE SEE FIG 20 CONNECT THE BATTERY TERMINALS SUGGESTION NEVER CONNECT THE BATTERY UNTIL YOU ARE READY TO START THE ENGINE SEAL THE BATTERY TERMINALS WITH PLASTIC TAPE TO AVOID THAT EVENTUAL VIBRATIONS MIGHT DISCONNECT THE TERMINALS ATTENTION PAY ATTENTION NOT TO SHORT CIRCUIT THE BATTERY TERMINALS AS BATTERY COULD BE DAMAGED BEYOND REPAIR 3 7 6 GROUND THE POWER PACK ATT
23. ial 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 A A A MAN 016 D 25 11 INSTRUCTIONS FOR THE DISASSEMBLY ASSEMBLY OF THE CLUTCH ATTENTION The following operations can be performed by a skilled mechanic under the conditions to have available the dedicated tools shown on the text otherwise it is necessary to apply to an Authorized Service Center Refer to the following drawing during the operations 12 11 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 A A A 10 9 8 7 6 5 4 3 2 1 OPERATIONS TOOLS Clutch disassembly 1 Remove the clutch cover 3 screws M6 Allen wrench 5mm T type 2 Remove the spark plug and replace with special tool to prevent crankshaft from turning Piston fitting P N 10271 3 Remove nut 1 nut M10 12 Point wrench 17 mm 4 Remove the external washer the drum with roller bearing the internal washer 5 Remove the special tool from the head and using the clutch wrench remove the 16x1 nut and the cone safety washer ATTENTION Turn clockwise as nut has left thread Clutch wrench P N 10270 24 mm socket 6 Apply clutch puller on clutch and remove clutch with 19mm socket
24. ng the track tests we recommend use of a tachometer recording the max obtained engine RPM Use sparkplug caps with a resistance of 5K 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 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 15000 RPM operating limit for the Leopard engine a sprocket ratio from 7 61 and 7 82 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 76 10 78 should be used or having a Z 11 on the engine sprocket a ratio 11 85 should be used MAN 016 D 30 MAN 016 D 31 15 SCHEDULED MAINTENANCE Following some simple maintenance standards will allow the engine to perform more reliably and have a longer life SCHEDULE COMPONENTS ACTIONS AND COMMENTS Before using Exhaust flexible Check status Exhaust springs Check status Exhaust strap Check status Exhaust muffler Check status and fixing Engine sprocket Check wear Che
25. of a sparkplug as lean or rich mixtures can generate the same final look which can also be achieved with a hot or cold sparkplug See table An excessively warm sparkplug shows the symptoms listed aside ATTENTION Always use a warmer than standard spark plug with cold or rainy climates Extremely clear color porous lock and calcification of the electrodes and of the internal insulation Irregularities in the ignition preignition and detonation with tendency to perforate the top of 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 MAN 016 D 28 An excessively cold sparkplug shows the symptoms listed aside ATTENTION Always use a colder than standard sparkplug with hot climates Insulator end and electrodes covered with black shady soot Ignition difficulties Note a wet or oily electrode could also mean an excessively rich mixture COMPARISON TABLE BASED ON THE THERMAL DEGREE HOT BOSCH NGK CHAMPION WO8CS BR9EG N54R WO7CS BR10EG N52R WO6CS BR11EG COLD 14 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
26. ox Keep the button pressed until the engine has got to a complete stop ATTENTION In case of rain it is necessary to protect the Power Pack Box with the water proof plastic cover as otherwise water by entering the box could damage the circuits beyond repair When weather is good remove the cover as the eventual condensation might damage the electrical circuits 7 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 time 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 8 INLET SILENCER Make sure that the inlet holes on the filter are towards the front of the kart and that they
27. strap damaged or lost Damaged exhaust header MAN 016 D 33 17 ENGINE PRESERVATION When engine is to remain unoperative for a long period it must be preserved as follows Disconnect the battery and charge it periodically see Par 12 Disconnect carburetor and clean it Seal with tape the engine inlet and exhaust The external of the engine must be cleaned Spray with protective oil the steel parts subject to oxidation Keep the engine in a dry ambient MAN 016 D 34 MAN 016 D 35 MAN 016 D 36 MAN 016 D 36
28. tion or coil failure Check Replace Bad H T coil grounding Check and tighten 2 grounds Power pack internal cable bad connection Apply to Authorized Service center Wet spark plug Replace Malfunction on induction system Check status and connections on fuel pipe Replace gaskets and membranes on carburetor Check reed petals Replace if necessary Engine starts when the start bottom is pressed but it stops when bottom is released Bad cable connections Check stator connector 4 ways Bad connections on Power Pack internal cables Apply to Authorized Service Center Bad carburetor adjustment I screw Check carburetor adjustment see par 5 The starter cranks after having released the start button Battery discharged starter relay does not disconnect Disconnect the positive terminal on battery and charge battery Rough idle Bad carburetor adjustment L Screw Check carburetor adjustment see par 5 Drop in engine performance Bad compression Check piston Bad carburetor adjustment Check carburetor adjustment see par 5 Insufficient gas flow Check gasoline flow lines Dirty inlet silencer Check and clean Burning smell smoke Overheating of clutch Check clutch Par 11 Clutch engages at too high RPMs Excessive wear of friction material Check clutch Par 11 Exhaust too noisy Flexible damaged Check and replace if necessary Springs damaged or lost Insulating
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