125cc RL - TaG - IAME USA West
Contents
1. mE MAN 043C Section 1 Section 2 Seclion 3 Section 4 ee o ROMS INDEX DESCRIPTION OF THE Parilla X30 125cc RL ENGINE Main features Characteristics of the Engine Operational limits Contents of packing Accessories Motor identification number PREPARATION amp INSTALLATION OF THE ENGINE ON THE CHASSIS Installation sketch of the engine on the chassis Install the water cooling system Exhaust header assembly Preparation and installation of the motor mount Install the carburettor Install the engine on the chassis Install the clutch cover with H T coil Mounting of the electric plant and connectors Install the intake silencer Install the exhaust ENGINE USE Charging of the oil in the gear box Gasoline and oil Carburetor adjustment guide Starting and stopping the engine Engine running in RPM limitation Inlet silencer Recommendations on the exhaust system Recommendations on the battery Warnings on the electrical system Spark plug and thermal degree Choice of the sprocket ratio ENGINE BASIC MAINTENANCE Centrifugal Clutch Instructions for the clutch disassemblyN assembly Gear timing schematic Replacement of the starter brushes Scheduled maintenance Troubleshooting Engine and accessories preservation Torque Value Wiring diagram MAN 043C 1 Section I DESCRIPTION OF THE Parilla X30 125cc RL TaG ENGINE 1 1 MAIN FEATURES The Par2. 043 35 4 4 REPLACEMENT OF THE STARTER BRUSHES OPERATIONS PICTURES 1 DISASSEMBLE THE STARTER UNSCREW 2 SCREWS M6x35 see Fig 1 5mm ALLEN WRENCH 5 see Fig 2 NOTE ON THE ENGINES MANUFACTURED AFTER SEPTEMBER 05 THE STARTER CAN BE REMOVED WITHOUT TAKING AWAY THE GEARS COVER BUT SIMPLY BY REMOVING THE COVER CLAMP see drawing 043 36 2 OPENING THE STARTER REMOVE THE PLASTIC CLAMP AND UNSCREW THE SCREW 4 FIXING THE INPUT CABLE TO THE STARTER see Fig 3 PHILLIPS SCREWDRIVER UNSCREW 3 SCREWS M5 C see Fig 4 PHILLIPS SCREWDRIVER 043 37 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 5 REMOVE ROTOR FROM STARTER HEAD see Fig 6 ATTENTION WHEN EXTRACTING ROTOR THE BRUSHES MAY SPRING OUT FROM THEIR SEATS REPLACING THE BRUSH A UNSCREW THE 2 SCREWS M4 D RETAINING THE PLATE E see Fig 7 PHILLIPS SCREWDRIVER REMOVE THE LITTLE RUBBER CAP F see Fig 8 PLIERS OUR SUGGESTION SLIGHTLY OIL THE TIN PLATE TERMINAL END TO MAKE EASIER THE EXTRACTION OF THE LITTLE RUBBER CAP Fig 7 MAN 043C 38 043 39 REMOVE SILICONE FROM BRUSHES WITH A SCREWDRIVER see Fig 9
3. 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 11 TO INSTALL THE THERMOSTAT REGULATING THE WATER TEMPERATURE CUT THE HOSE CONNECTING THE FITTING ON THE RADIATOR INLET AND THE FITTING ON THE ENGINE OUTLET INSTALL THE THERMOSTAT SO THAT THE ARROW IS TURNED TOWARDS THE RADIATOR SEE FIG 12 TIGHTEN WITH STEEL CLAMPS ON BOTH SIDES 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 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 running in check the water level in the radiator and top up if necessary In the event of a long inactivity of the engine remove the hoses and empty the water circuit to avoid damages to the engine or parts due to cold temperature 043 11 EXHAUST HEADER ASSEMBLY NOTE THE ENGINE IS SUPPLIED WITH THE EXHAUST OF THE ENGINE ARE PROTECTED BY A BLIND GASKET SEE FIG 1 2 3 1 REMOVE THE NUTS AND THE EXHAUST COVER 2
4. 8 68 8 89 9 11 9 32 9 54 9 75 during tests Oo O gt ass ars 887 921 s ase 24 825 2 1 1 13800 1 O gt Io 9 59 9 82 63 6 85 7 49 7 72 7 93 8 16 837 8 58 881 9 02 9 24 9 46 968 9 89 1 x 954 8 16 14200 7 93 14400 14600 14800 15000 15200 15400 15600 15800 16000 16200 16400 16600 16800 17000 6 23 6 45 6 65 6 86 7 08 7 28 7 50 7 71 772 199 675 8 ME 665 685 7 08 128 771 758 622 61 680 oT 575 895 693 673 6 63 32 6 75 6 45 6 36 YT 8 39 8 98 917 867 9 823 844 64 7 95 783 1771 760 7 49 7 28 718 7 08 6 98 6 89 680 5 82 6 02 6 22 6 41 6 61 5 67 5 87 5 60 5 79 619 610 602 75 5 95 6 14 6 33 6 53 6 71 7 31 7 5 587 7 02 572 684 760 5 53 5 72 5 91 6 09 6 28 6 46 6 84 72 7 60 7 78 8 53 872 6 8 6 73 6 5 65 948 935 922 910 819 898 671 7 808 8 6 6 44 7 02 7 22 7 40 8 18 8 94 6 54 3 7 88 864 6 46 778 859 2 7 68 843 852 522 843 0 6 80 7 01 7 41 7 60 0 x 8 08 867 8 86 9 05 9 9 6 6 6 58 6 76 6 95 5 40 6 13 6 68 8 14 8 32 8 50 642 660 6 78 68 7 634 5 6 EJEZI
5. 809 742 90 900 818 75 80 800 727 6 67 For the operation limit max of 14 000 15 500 16 000 RPM the following table Tab 2a 2b 2c has been prepared SUGGESTION During the track tests we recommend use of a tachometer recording the max obtained engine RPM Use spark plug caps with a resistance of 5 to avoid the eventual interferences between the engine ignition and the tachometer and or telemetry MAN 043C 30 The following example should clarify the procedure for the optimization of the sprocket ratio Assume to use the engine with Z 10 teeth engine sprocket and that during the preliminary track tests a Z 77 teeth axle sprocket has been used From Table 1 with Z 10 as engine sprocket and Z 77 on the axle sprocket a ratio of 7 70 is found Make a few laps on the track and record the maximum engine rpm achieved Let us assume that you detect 13 600 RPM From the Table 2a to achieve a max RPM of 14 000 RPM operating limit for the 1 engine X30 version a sprocket ratio between 7 83 and 8 05 should be used having used during the tests a sprocket ratio of 7 7 and having achieved 13 600 RPM From Table 1 with these values a sprocket ratio of 10 78 10 80 should be used or having a Z 11 on the engine sprocket a ratio 11 87 should be used Sprocket ratio to achieve max 14000 RPM Sprocket ratio Engine max RPM 32 6 54 6 75 7 18 7 38 32 8 04 8 25 8 46
6. counterclockwise until 2 000 2 500 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 Ro iy ery feler o drm ene 1 8 4 acceleration 4 acceleration MAN 043C 23 3 4 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 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 WARNING 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 necessa fo replace the complete assembly The starting procedure trom 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 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 s
7. 3 2 MAKE SURE THE EXHAUST GASKET IS IN SEAT AND INSTALL THE EXHAUST HEADER SEE FIG 2 2 3 3 INSTALL THE TWO WASHERS 8mm 2 3 4 INSTALL THE TWO 2 NUTS 8 13mm SOCKET WRENCH OR 13 mm OPEN WRENCH TORQUE 18 22 Nm 160 190 in lb PREPARATION AND INSTALLATON OF THE MOTOR MOUNT NOTE ALL THE DIMENSIONS ARE IN MILLIMETERS 2 4 1 DRILL 4 HOLES DIAM 8 25 8 5mm IN THE MOTOR MOUNT 043 12 2 4 2 INSTALL THE MOTORMOUNT mm ALLEN WRENCH SURE TO USE THE M8 ALLEN SCREWS WITH A LENGHT SUCH AS TO ENGAGE IN THE CRANKCASE A THREADED LENGHT OF 16 19mm THE SCREW MUST PROTRUDE FROM THE PLATE FOR 16 19 SEE FIG 3 AND DRAW PAG 11 4 ALLEN SCREWS M8 TORQUE AT 22 24 Nm 190 210 in b INSTALL THE CARBURETOR 2 5 1 REMOVE THE PLASTIC PLUG FROM THE INLET MANIFOLD SEE FIG 4 WARNING MAKE SURE THAT THE PRESSURE HOLE ON THE GASKET IS NOT PLUGGED 2 5 2 INSTALL THE CARBURETOR 5 mm ALLEN TWO 2 NUTS M AND TWO WASHERS SEE FIG 5 TORQUE 10 Nm 50 90 inb A WARNING 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 MAN O43C 13 2 6 INSTALL THE ENGINE ON THE CHASSIS 2 6 1 POSITION THE ENGINE ON THE TWO OUTSIDE MAIN RAILS AND FIX THE MOTOR MOUNT WITH TWO CLAMPS SEE FIG 6 S
8. 30 650 668 o4 533 552 569 sar 606 622 642 660 se sss 7 732 7 50 768 758 805 922 2 4 043 31 Sprocket ratio to achieve max 15500 RPM Sprocket ratio Engine max RPM 5 1 59 6 1 6 29 6 48 6 67 6 7 26 7 45 7 64 7 84 8 03 8 22 8 42 8 61 8 8 during tests 13400 660 682 728 7 50 7 72 ss 840 862 844 907 929 91 974 9 96 10 10 6 13800 6 l 14000 653 675 ese 7 7 73e 752 804 825 846 86s 0 922 958 974 956 14200 623 644 sse 707 7 28 750 7 71 782 857 919 040 set 92 14400 4 2 14600 5 HH HE X e77 638 78 739 760 7 amp 1 802 822 864 885 96 927 947 959 14800 HB 5 918 929 959 679 sso 7 1 7 39 7 60 7 00 sco 821 841 861 882 902 922 949 so 6 10 30 so 670 69 7 10 7 20 750 70 810 830 849 870 so 929 930 2 15000 15200 15400 575 594 614 63 652 671 6 7 11 73 750 7 9 749 808 827 847 867 896 996 57 57 25 7 64 7 84 822 842 851 880 9 00 567 585 05 625 644 669 663 7 01 7 21 740 759 779 758 847 837 855 874 854 553 572 591 828 646 668 see 708 vzz 740 740 776 756 816 834 858 872 540 558 577 594612 630 649 667 64674472741 759177 7 96 8 4 83
9. THE STARTER ROTOR ROTATES FREELY CONNECT THE INPUT WIRING TO THE STARTER WITH THE SCREW M4 see Fig 19 PHILLIPS SCREWDRIVER SECURE THE WIRE TO THE STARTER BY MEANS OF A PLASTIC CLAMP see Fig 20 ASSEMBLING THE STARTER PLACE THE STARTER INTO THE CRANKCASE see Fig 20 OIL O RING TO MAKE EASIER INSTALLATION N 2 SCREWS TCH M x35 TIGHTEN AT 8 10 Nm 70 90 inb 5 WRENCH T TYPE 043 43 4 5 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 Check wear Engine sprocket Check alignment with axle sprocket Engine chain Check wear tensioning and oil chain Check status and charge Cables and connectors Check status and connectors Grounding of engine status and connectors electronic box After use Battery Remove cover see fig and clean internally Every 5 10 hours Bendix assembly Exhaust muffler Remove muffler end clean Inlet silencer Open clean Open clean FL Every 20 hours Gears replace worn parts Balance shaft Check and replace worn parts 043 44 4 6 TROUBLESHOOTING Below are some common faults their probable causes and suggested remedy FAULTS PROBABLE CAUSES REMEDY Starter will not crank when turning Bad connections on
10. at half straight cover with the hand for an instant the holes on the inlet silencer keeping the throttle wide open A WARNING Once running in is over and the engine is cold check the torque of the exhaust header nuts as during the running in the nuts fend fo become loose refer fo the attached table 3 6 RPM LIMITATION The electronic box incorporates an RPM limiter which prevents the engine from exceeding 14 000 15 500 or 16 000 RPM depending on the engine versions This limit cannot be exceeded otherwise the engine could be damaged by the extremely high RPM Ad VARNING 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 which has to be equal fo the engine version max rotation limit i e 14 000 15 500 or 16 000 so that the incorporated limiter is not switched on continuously when the engine is running 3 7 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 Regularly clean the inside from oil deposits If necessary remove the rubber manifold with filter and clean it with gasoline or solvent MAN 043C 25 3 8 EXHAUST SYSTEM Before eac
11. 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 protected 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 14 000 15 500 or 16 000 RPM during use depending on the engine versions 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 the Bendix which engages the starter wheel 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 carburetor specially designed for this engine and includes an integral fuel pump filter and an all position mounting capability The battery 12 V 9 Ah is a sealed no maintenance one and is not supplied with the engine it has to be allocated in the 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 043C 2
12. 1 2 CHARACTERISTICS OF THE ENGINE OPERATIONAL LIMITS The characteristics of the engine are the following Cycle Original cubic capacity Original bore Max theoretical bore Stroke Lubrication Induction Carburettor Cooling Ignition Battery charge Electric start Clutch Operational limits e Max RPM OTTO 2 stroke 123 67 cc 125cc max 54 00 mm 54 28 mm 54 00 mm Fuel oil mix 4 25 1 Reed valve in the crankcase Membrane TRYTON HOBBY 27 C 226 Water forced Digital with integrated rev limiter With integral generator 12V 0 30 Kw Automatic dry centrifugal 14 000 15 500 and 16 000 with rev limiter depending on the versions e Min water temperature 45 C e Max water temperature 65 C WARNING Never exceed the above limits no obligation of AME exists in case the above limits are exceeded 043 3 1 3 CONTENTS OF THE PACKING Each Parilla X30 engine is supplied with the accessories under shown e Exhaust monifold 0 S lo INDUCTION ELECTRICALPLANT o e Fxngdoms 08 005 MISCELLANEOUS 1 e Radiator e Radiator l e Radiator support kit e Complete pump group 043 4 1 4 ACCESSORIES SPARK PLUG KIT ELECTRIC PLANT x mt Q RADIATOR SUPPORT KIT WATER HOSES KIT 043 5 WATER PUMP ASSEMBLY RADIATOR 1 5
13. 2 st 70587 605 15600 15800 16000 16200 16400 16600 16800 17000 533 805 9234 659 678 696 7 13 7 22 7 50 7 68 7 86 822 840 13000 _ 1320 13400 13600 13800 400 14200 14400 1460 14800 1500 590 15200 1540 15600 15800 1600 16200 1640 1600 16800 7000 Sprocket ratio to achieve max 16000 RPM Sprocket ratio Engine max RPM 5 93 5 72 5 91 6 28 6 47 7 03 7 22 7 41 7 59 7 78 7 97 8 16 834 8 53 8 72 during tests mmo 670 699 7 16 7 38 7 61 7 84 829 875 859 20 848 866 10 1 1034 1057 19400 ros 7 27 150 7 95 8 7 839 862 885 205 829 852 974 10 9 10 41 5 53 572 29628 647 685 68 5 551 870 587 05 624 642 959 956714732 vso 7 68 7 87 84 822 840 520 538 556 573 59 69 827 844 862 880687 714 7 32 750 798 7s5 803 821 1 o 4 gt ES pu O 16200 16400 16600 16800 17000 043 32 Section 4 BASIC MAINTENANCE 4 1 CENTRIFUGAL CLUTCH The engine has a low maintenance dry centrifugal clutch The following prescriptions if carefully followed will allow a clutch longlife When starting the engine make sure that the brake pedal is fully pressed to avoid sudden accelerations A WARNING Once the engine is started avoid useless accelerations wh
14. 29 3 12 CHOICE OF THE BEST SPROCKET RATIO The life of an engine depends on many factors but most of all upon the speed at which the engine is operated If an engine is normally operated at speed 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 operating limits imposed by the manvfacturer The operating limit for the PARILLA X30 engine are respectively 14 000 Rpm 15 500 Rpm 16 000 Rpm According to the different engine versions WARNING Never exceed the above limit No obligation of IAME 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 11 teeth sproket pitch 7 775 mm but 10 and 12 teeth sprockets are available as accessories Table 1 shows the various ratios between the sprocket on the axle and the engine sprocket given the different axle sprocket Tab 1 Sprocket Teeth n Enai ket a eeth n ngine sprocke Sprocket ratio Teeth n Engine sprocket Teeth n Teeth n Axle sprocket 10 11 12 Axle sprocket 10 11 12 72 720 655 6 86 860 782 717 89 890
15. 7 8 ELECTRONIC BOX RELAY STARTER KEY FUSE HOLDER BATTERY IGNITION STARTER MOTOR H T COIL MAN 043C 48
16. 8x45 WITH WASHER AND NUT ON THE PUMP BRACKET ON THE REAR CROSS RAIL SEE FIG 1 TORQUE AT 18 22 Nm 160 190 in lb IN CASE THERE IS NO BRACKET FOR THIS PURPOSE IT IS NECESSARY TO INSTALL THE PUMP ON REMOVABLE CLAMPS AVAILABLE IN DIFFERENT DIAMETERS 28 30 32mm ASSEMBLE THE PUMP FIXING BRACKET ON THE CLAMP N 2 SCREWS M x12 AND PLACE THE CLAMPS ON THE REAR CROSS RAIL N 2 SCREWS M6x25 INSTALL THE PUMP ON THE BRACKET N 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 11 SCREWMEXA5 M8X45 a p _ 144 SCREW M6 Fig 2 Ls INSTALL THE DRIVING PULLEY ON THE AXLE 2 CLAMPS AVAILABLE IN DIFFERENT DIAMETERS 230 35 40 50mm ALIGNING ITS RACE WITH THE DRIVEN PULLEY ON THE PUMP SEE FIG 3 FIX THE TWO CLAMPS WITH 2 SCREWS M5x22 TIGHTEN 6 8 Nm 50 70 in lb TIGHTEN THE TWO SCREWS M6x25 ON THE PUMP FIXING CLAMPS AND THE SCREWS M x12 ON THE PUMP FIXING BRACKET TIGHTEN 8 10 Nm 70 90 inb MAN 043C 8 INSTALL THE BELTS AND TENSION SEE FIG 4 TIGHTEN THE SCREW M8x45 TORQUE 18 22 Nm 160 190 in lb BEFORE INSTALLING THE RADIATOR PREASSEMBLE THE FOLLOWING COMPONENTS INSERT THE 4 RUBBER DAMPENERS INTO THE FIXING HOLES ON THE RADIATOR RUBBER DAMPENER SEE FIG 5 PLACE THE RADIATO
17. Center Refer to the following drawing during the operations 1 Drum nut 9 Clutch body 2 External washer Clutch drum 10 Starter ring 3 Roller cage Internal washer 11 Screw 4 Sprocket Locking nut OPERATIONS TOOLS Clutch disassembly 1 Remove the clutch cover 3 screws Allen wrench 5mm T type 2 Remove the Bendix support and replace it with starter wheel locking fool Starter wheel locking tool S884 3 Remove nut 1 nut M10 12 point wrench 17 mm 4 Remove the external washer the drum complete with roller cage the internal washer 5 Remove the special tool from the head and using Starter wheel locking tool S884 clutch wrench remove the M20x1 nut and the starter 30mm socket wheel WARNING turn clockwise as the nut has left thread Apply the clutch puller on clutch hub and remove the Clutch puller ATT 026 clutch hub with the starter wheel 12 point wrench 12mm 7 Remove the starter wheel 3 screws M6 12 point wrench 5mm 043 34 Before assembling the clutch wash with diluent the shaft taper the connecting hole on the clutch body the clutch drum and the starter wheel 1 2 3 Install clutch Install the starter wheel on the clutch hub by matching 12 point wrench 10 mm the three holes and the dragging pin 3 screws M6 torque at 10 Nm 90 in lb ATTENTION make sure to always install the 7 apply Loctite on the thread
18. ENGINE IDENTIFICATION NUMBER The official motor identification number can be found stamped on 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 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 fo the Motor Identification Number and fo the mofor model 043 6 Section 2 PREPARATION AND INSTALLATION OF THE ENGINE ON THE CHASSIS NOTE In case the engine is supplied already assembled on the chassis it is af care of the assembler fo follow these instructions The tinal customer in this case can skip this section and can start reading from section 3 Whenever the engine or a component is disassembled it is necessary to always follow the under shown instructions for proper reassembly 2 1 INSTALLATION SKETCH OF THE ENGINE ON THE CHASSIS CHASSIS RIGHT SIDE CHASSIS LEFT SIDE MAN 043C 7 2 2 INSTALL THE WATER COOLING SYSTEM NOTE to install the water pump belts it is necessary fo remove the rear axle REINSTALL THE REAR AXLE AFTER HAVING Fig 1 INSERTED TWO BELTS SUGGESTION INSTALL TWO EXTRA BELTS AS SPARES AND FIX THEM WITH TAPE TO THE AXLE INSTALL THE WATER PUMP 1 SCREW M
19. HIS OPERATION IS FUNDAMENTAL AS AN IMPROPER GROUNDING COULD IRREPARABLY DAMAGE THE CELECTRONIC BOX FIX THE BUTTONHOLE END OF THE SECOND GROUND CABLE TO THE H T COIL THROUGH THE 6 NUT OF THE COIL FIG 28 TORQUE AT 8 10 Nm 70 90 inb WARNING THIS OPERATION IS FUNDAMENTAL AS AN IMPROPER GROUNDING COULD IRREPARABLY DAMAGE THE CELECTRONIC BOX CONNECT THE PIN OF THE CABLE OF DELIVRED BY THE H T COIL TO THE CABLE COMING FROM THE CABLES HARNESS FIG 29 WARNING USE A PLASTIC CLAMP TO FIX THE CABLE ON THE COM TO AVOID THE ACCIDENTAL RELEASE OF THE PINS FIG 30 ALLEN WRENCH 5 mm TUBE KEY 10mm Fig 28 Y a k 043 19 2 9 INLET SILENCER MOUNTING 1 CONNECT THE ELECTRONIC BOX TO THE 20 3 POLES CONNECTOR THE CABLES HARNESS FIG 31 CONNECT THE STARTER RELAY TO THE 4 POLES PIN ON THE CABLES HARNESS FIG 32 Fig 31 2 Fig 32 WARNING MAKE SURE THAT THE SECURITY FLAPS SNAP TO GUARANTEE THE CORRECT CONTACT OF THE TWO ENDS AND A SAFE TIGHTENING CONNECT THE PIN OF THE KEY BLOCK TO THE 8 POLES PIN FROM THE CABLES HARNESS FIG 33 WARNING MAKE SURE THAT THE SECURITY FLAPS SNAP TO GUARANTEE THE CORRECT CONTACT OF THE TWO ENDS AND A SAFE TIGHTENING SCREW THE SPARK PLUG CAP ON THE H T COIL CABLE FIG 34 aa 1 FIX THE SPARK PLUG CAP ON THE COIL CABLE WITH A PLASTIC CLAMP FIG 35 e M
20. OUNT THE SPARK PLUG PROVIDED WITH THE ENGINE AND TORQUE A 20 26 Nm 175 230 in lb PLACE THE SPARK PLUG CAP ON THE SPARK PLUG MAKE SURE THAT THE INTAKE SILENCER 15 POSITIONED WITH THE HOLES UPSIDE AND THAT THEY ARE NOT OBSTRUCTED TIGHTEN THE CLAMP ON THE CARBURETTOR AND FIX THE INLET SILENCER WITH THE DEDICATED CLAMP ON THE CHASSIS TUBE FIG 36 MAN 043C 20 2 10 INSTALL THE EXHAUST NOTE SEE SECTION 3 8 FOR THE RECOMMENDATIONS ON THE IDEAL EXHAUST LENGHT 2 10 1 INSTALL THE FLEXIBLE L 65mm FLEXIBLE COMPLETELY CLOSED AND THE EXHAUST HEADER SEE FIG 37 AND FIT THE INSULATING SLEEVE ON THE FLEXIBLE FLEXIBLE SEE FIG 38 INSULATING SLEEVE 2 10 2 INSERT THE FLEXIBLE ON THE EXHAUST HEADER AND FIX WITH THE 3 SPRINGS k gt SEE FIG 39 rti 2 E lt i m I 4 www 4 47 4 d gt THE ENGINE IS READY TO BE STARTED 043 21 Seclion 3 USE OF THE ENGINE 3 1 CHARGING OF THE OIL IN THE GEARBOX Mb voc The engine is suplied without oil in the gear box Before starting the engine fill the box wilh SAE 30 oil Starting the engine with a dry box will damage the gears beyond repair Charge of the gear box Put the engine in horizontal position unscrew the oil plug n 1 on the picture and oil level gt plug n 2 on the picture fill with oil until it 4 co
21. R SUPPORT BRACKET BETWEEN THE RADIATOR FIXINCS BY TILTING ONE END AND INSERTING IT THROUCH THE RUBBER DAMPENERS SEE FIG 6 NOTE THE BRACKET ENDS AND THE DAMPENERS HOLES RADIATOR SUPPORT BRACKET MAN 043C 9 COMPLETE INSERTION OF THE RADIATOR SUPPORT BRACKET IN THE RUBBER DAMPENERS SEE FIG 7 AND 8 FX THE RADIATOR SUPPORT BRACKET INSERTING ALSO THE RADIATOR FIXING BRACKET RADIATOR CAP SIDE 1 SCREW M6x90 AND N 1 SCREW 85 WITH NUT INSTALL THE L SHAPE BRACKET 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 RADIATOR FIX BRACKET SCREW M6X90 SCREW M6X12 SCREW M8X20 m SCREW M6X85 LOWER FIXING CLAMP MAN 043C 10 PLACE THE RADIATOR FIXING CLAMP ON THE CHASSIS SIDE RAIL BRAKE SIDE N 2 SCREWS 6 25 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 M8 ONCE YOU FIND THE CORRECT POSITION TIGHTEN THE M x25 SCREWS ON THE LOWER CLAMP FIXING THE RADIATOR TIGHTEN AT 8 10 Nm 70 90 in lb 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
22. REMOVE SPRINGS MAKING PRESSURE EXTERNALLY ON THE TIN PLATE TERMINAL REMOVE BRUSH see Fig 10 INSTALL NEW BRUSH TERMINAL INSIDE see Fig 11 PLACE LITTLE RUBBER CAP ON THE TERMINAL REINSTALL THE PLATE AND FIXE IT WITH THE 2 SCREWS M4 see Fig 12 PHILLIPS SCREWDRIVER 043 40 043 41 REPLACEMENT OF THE BRUSH B UNLOOSE THE SCREW see Fig 13 EXTRACT THE BRUSH HX THE NEW BRUSH WITH SCREW M3 PHILLIPS 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 B u 1 see Fig 1 4 1 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 15 OUR SUGGESTION TO IMPROVE THE BRUSHES LIFE SECURE THE LITTLE WIRES WITH SILICONE see Fig 16 043 42 CHECK THAT O RING 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 17 SCREW THE 3 SCREWS M5 see Fig 18 PHILLIPS SCREWDRIVER CHECK THAT
23. THE EXHAUST AS THE EXCESSIVE HEAT COULD DAMAGE THE COIL BEYOND REPAIR 043 15 MOUNTING OF THE ELECTRIC PLANT AND CONNECTORS complete scheme in the drawing at the end of the document NOTE For a correct installation follow the under shown instructions MOUNT THE SILENT BLOCKS ON THE UPPER CLAMP FIG 13 COMPLETE THE MOUNTING OF THE CLAMPS ON THE BATTERY SUPPORT WITH THE N 4 SCREWS M 6x25 2 SCREWS FOR EACH CLAMP FIG 14 TORQUE AT 6 8 Nm 50 70 in lb WRENCH 4mm NOTA THE DIFFERENT HOLES ON THE SUPPORT ALLOW TO ADAPT THE THE SYSTEM TO CHASSIS PLACE THE SUPPORT PLATE ON THE SUPPORT AND FIX THROUGH THE N 3 SCREWS M5x10 AND CONCERNED WASHERS AND NUTS TORQUE 6 8 Nm 50 70 in lb WRENCH 4mm PLACE THE ELECTRONIC BOX ON THE PLATE AND FIX IT THROUGH THE N 2 SCREWS M5x15 E AND CONCEARNED WASHERS AND SELF LOCKING NUTS TORQUE 6 8 Nm 50 70 in lb WRENCH 4mm WARNING THE CABLES HARNESS DOESN T HAVE TO GET IN CONTACT WITH THE SOIL OR WITH ROLLING PARTS TO AVOID IRREPARABLE DAMAGES DRILL A HOLE 6mm IN THE FRONT PART OF THE RELAY BOX AS SHOWN IN THE PICTURE AND FIX THE RELAY THROUGH THE SCREW M5x20 WITH WASHER ON THE PLATE Fig 17 TORQUE 6 8 Nm 50 70 in lb 043 16 PLACE THE PLASTIC CLAMPS THE DEDICATED HOLES AND PUT THE FUSE HOLDER IN POSITION AND THEN TIGHTEN THE PLASTIC CLAMPS TO FI
24. TLE H HIGH SPEED FUEL MIXTURE SPEED SCREW 1TO RICH 2 LEAN 1 e 3A T O 1 5 TURNS OPEN Normally the correct setting of the mixture screws after engine run in is the following close the screw completely and then open 1 1 turn H close the screw completely and then open 1 1 6 1 turn and 10 Based on various factors as altitude ambient temperature etc It might be necessary to reset the carburetor to optimize the performance of the engine A WARNING Never lean too much as lean mixture will overheat engine and cause seizure Do not force H or L closed ff may damage the precision machined orifice and render the carb inserviceable The adjustment of screw must be performed with warm engine H L I Adjust T O from closed to Adjust T O from closed to approximately Close by further 1 gt approximately 1 1 6 T O 1 T O 1 turn after contact with throttle 1 turn and 10 lever Start the engine and warm it If RPM too high adjust counterclockwise until clutch is disengaged Continue to turn clockwise until max RPM is reached Adjust c c w fractionally for rich idle Turn c c w until max RPM is reached Adjust further fractionally for rich idle Trigger accelerator decreases L Slowly adjust clockwise increases Engine is now idling at max attainable RPM or slightly lower on rich side Adjust
25. UGGESTION NEVER TORQUE COMPLETELY THE CLAMPS UNTIL THE CHAIN IS INSTALLED AND PROPERLY ALIGNED 2 6 0 CHECK THE ALIGNMENT OF THE ENGINE SPROCKET AND THE AXLE SPROCKET WITH A STRAICHT EDGE SEE FIG 7 2 6 4 MOVE THE ENGINE ON THE RAILS AND OPTIMIZE THE CHAIN TENSION WARNING THE PLAY OF THE CHAIN MUST BE APPR 15mm 124 24 MEASURED IN THE SHOWN POINT SEE FIG 9 2 6 5 TORQUE THE CLAMP SCREWS 2 6 3 INSTALL THE CHAIN PITCH 7 775 SEE FIG 8 043 14 2 7 INSTALL THE CLUTCH COVER WITH 5mm ALLEN H T COIL Fig 10 2 7 1 REMOVE THE 3 SCREWS M x25 ON THE v CRANKCASE SEE FIG 10 AND INSTALL THE CLUTCH COVER WITH H T COIL SEE FIG 11 TORQUE THE 3 SCREWS AT 8 10 Nm 70 90 in lb NOTE IF AN HORIZONTAL MOTOR MOUNT IS USED CHECK AND SEE IF THERE IS SUFFICIENT SPACE BETWEEN THE CHAIN AND THE UPPER PART OF THE CLUTCH COVER IF THIS IS LOWER THAN 6 7 mm WIDEN THE CHAIN OPENING WITH A FILE TO CHECK THIS WE SUGGEST TO INSTALL THE SPROCKET WITH THE HIGHEST AVAILABLE TOOTH NUMBER 5 mm ALLEN 2 7 2 CONNECT THE COIL COPPER CABLE ON THE HOLE ON THE CRANKCASE SCREW Fig 12 M x12 SEE FIG 12 TORQUE AT 8 10 Nm 70 90 in lb WARNING 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 HAS BEEN CHOSEN TO BE AS FAR AS POSSIBLE FROM
26. X THE FUSE CASE CUT OFF EXCEEDING PLASTIC CLAMPS Fig 18 MOUNT THE KEY BLOCK IN THE DEDICATED HOUSING Fig 19 SLIDE THE BATTERY FIXING STRIPE IN THE DEDICATED SLOTS Fig 20 PLACE THE BATTERY IN THE DEDICATED SLOT Fig 21 PLACE THE CABLES AT DESIRED CONVENIENCE IN A PRACTICAL AND SAFE WAY AND TIGHTEN THE BATTERY STRIPE ADVICE CONNECT THE BATTERY ONLY BEFORE STARTING THE ENGINE PROTECT THE CONNECTIONS ON THE BATTERY WITH ISOLATING TAPE TO AVOID ACCIDENTAL RELEASE OF THE FASTONS MAN O43C 17 CONNECT THE STATOR PIN WITH THE PIN ON THE CABLES HARNESS Fig 23 FIG 23 CONNECT THE STARTER MOTOR PIN WITH ITS CORRESPONDING ON THE CABLES HARNESS FIG 24 WARNING MAKE SURE THAT THE SECURITY FLAPS SNAP TO GUARANTEE THE CORRECT CONTACT OF THE TWO ENDS AND A SAFE TIGHTENING VERIFY THE PRESENCE OF THE PLASTIC CLAMP ON THE STARTER MOTOR AND THAT IT FIXES THE CABLE ON THE BODY OF THE STARTER ENGINE FIG 25 WARNING THIS OPERATION IS VERY IMPORTANT AS THE VIBRATIONS COULD CAUSE DAMAGES TO THE INTERNAL STARTER MOTOR CONNECTIONS PLACE THE GROUND CABLE BUTTONHOLE END 6 5mm ON THE BACK OF THE ENGINE FIG 26 043 18 FIX THE BUTTONHOLE END OF THE GROUND CABLE THROUGH THE M x12 SCREW PRESENT ON THE STARTER ENGINE FIG 27 TORQUE 8 10 Nm 70 90 in lb WARNING T
27. attery terminals Other recommendations 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 n case the electrolyte diluted Sulfuric Acid gets in contact with skin or clothes wash immediately 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 oxydized or damaged When the battery comes to an end never throw it in the garbage but deliver it to an authorized disposer 043 27 3 10 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 WARNING If these prescriptions are not followed the electrical system and the engine could be damaged beyond repair No obligation of 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
28. emain unoperative for a long period it must be preserved as follow Disconnect the battery and charge it periodically see sect 3 9 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 In the event of a long unoperative period of the engine release the hose fixed between the water pump inlet and the radiator outlet as shown in the picture and empty the water circuit to avoid damages to the engine and the accessories due to freezing 043 46 4 8 TORQUE VALUES NOMINAL SIZE Q TY FASTENER NAME WRENCH VALUES Nm VALUES in ib M14 1 25 1 Spark plug 20 8 20 26 175 230 8 1 25 ead and cylinder nut 18 22 160 190 M8 x 1 25 Exhaust nut IG ZZ 1800 TED MO x 1 Reed group screw 70 50 M amp x1 2 fixing stud bolt 6 10 50 90 MS x 0 8 M10 x 1 Ign Digit K rotor fixing nut Hex 17 20 26 175 230 M6 x 1 Bendix support screw Alen 5 6 8 Starter fixing screw Allen 5 B y Z 38 Clutch cover fixing screw Allen 5 JO ZW ge Clutch drum holding nut Starter ring fixing nut o M5 x 0 8 Bal shaft bearing fix screw Allen 3 6 8 Coil fixing nut 043 47 ADN AN 1 i 1 2 3 4 5 6
29. 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 correctly fix the H T 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 9 The digital assembly needs use of a 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 5A strip fuse Use of fuses wi
30. f 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 See table An excessive warm spark plug shows the symptoms Extremely clear colour porous look and listed aside calcification of the electrodes and of the internal insulation WARNING Irregularities in the ignition preignition and Always use a warmer than standard spark plug with detonation with tendency to perforate the top of the cold or rainy climate piston Note some of these sympfoms 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 symptoms Insulator end and electrodes covered with black listed aside shady soot Ignition difficulties WARNING Nofe a wet or oily electrode could also mean an Always vse a colder than standard spark plug with excessively rich mixture hot climates COMPARISON TABLE BASED ON THE THERMAL DEGREE HOT 5 WO8CS BROEG N54R WO7CS BRIOEG N52R WO6CS BRI TEG COLD MAN 043C
31. h test make sure that the flexible is not damaged Replace if necessary A WARNING In case the flexible is damaged metallic particles could be sucked the engine and Cause 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 pertormance is achieved with a total exhaust lenght of L 450 455 mm Where L is measured trom 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 the low RPM 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 5mm per time MAN 043C 26 3 9 BATTERY The battery 12 V 9 Ah is sealed and without maintenance battery not included in the eng
32. ich can overheat and deteriorate the clutch Oil the chain before each session Immediately affer each race or fest 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 irreparably the sprocket Check the clutch every 5 hours of use When metallic noises are heard inside the clutch It 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 83mm 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 WARNING In case the friction material has been totally worn out and there has been a metal contact between clutch body and the clutch drum it is necessary fo replace clutch drum See drawing MIN 983 mm MAN 043C 33 4 2 INSTRUCTIONS FOR THE DISASSEMBLY ASSEMBLY OF THE CLUTCH A WARNING the following operations can be performed by a skilled mechanic under the conditions to have available the dedicated fools shown the text otherwise it is necessary fo apply to an Authorized Service
33. illa X30 has been expressly designed and tuned for powering the karts for hobby racing on closed tracks destined for this specific purpose When designing this new engine we have considered the technical solutions already adopted for the high performance engines and the experience acquired with the TaG engines Touch and Go This in order to guarantee the highest reliability of components when the operating limits are respected This engine is a 2 stroke single cylinder The cylinder and the crankcase are in aluminium alloy The pressed liner is made of centrifugated cast iron fully machined to guarantee the best possible stability and sliding surface The head is separated from the cylinder and secured by 4 studs The crankshaft is built and supported by two ball bearings The crankshaft is of steel alloy hardened and tempered as the connecting rod machined from the full which runs on roller bearings The crankcase houses a balance shaft driven by two gears which rotates opposite to the crankshaft thus reducing the engine vibrations 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
34. ine package In order to lenghten the battery life it is recommended to follow few suggestions When the tension drops below 12 6V it is necessary to recharge the battery Max allowed recharging current is 1 8A ideal recharge is achieved with an average charging current of 0 8 1 A recharging time of appr 1O h and at an ambient temperature between O 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 outlet current 2 full charge During transportation or storage the battery could loose its charge due to the self discharge 0 1 max per day Fully recharge battery before use wARNING Always connect the negative terminal before and the pole positive terminal after Always disconnect the battery in opposite order Recharge the battery at least once every 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 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 b
35. mes out from the oil level plug appr 40cc dim of oil ii Use a SAE 30 motor oil Check the oil level Put the engine in horizontal position and unscrew the oil level plug It the level is correct you should see a light outcome of oil otherwise top up Discharge the oil Unscrew the oil level plug and loosen the charge plug Tilt the engine to discharge the oil through the oil level plug 3 2 GASOLINE AND OIL Use leaded or unleaded Premium gasoline 95 ROM mixed with oil at 4 25 1 Use oils containing Castor Oil which guarantees an optimized lubrication at high temperature 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 ELF HTX 909 K ERG KART FORMULA Once the fuel tank is filled make sure that the gasoline reaches the carburetor before starting the engine Never use the electric starter to suck the gasoline as this could discharge the battery SUGGESTION Disconnect the plastic tube on the carb and the vent tube on the tank and pressurize the vent tube until the gasoline comes out from the tube on the carb Make sure that there is no air in the tube Connect the tube on the carb and on the vent 043 22 3 3 CARBURETOR ADJUSTMENT GUIDE L LOW SPEED FUEL MIXTURE I THROT
36. s mm dragging pin as otherwise the eventual kick backs could break the screws Install clutch body and the cone safety washer Apply Loctite 641 for coaxial lockings Install the clutch body fixing nut and starter wheel Starter wheel locking tool S 884 using the 30mm clutch wrench 12 point wrench 30 mm A torque at 100 110 Nm 885 970 in 4 5 ATTENTION turn counferclockwise as nut has b thread Install the internal washer ATTENTION install washer with bevel fowards internal part of the engine Clean the roller cage and grease it before installing it on the crankshaft Install the clutch drum and the external washer ATTENTION install washer with bevel towards internal part of the engine Install the starter wheel locking ool to prevent the shaft Starter wheel locking tool 5 884 17 mm socket from turning and install the clutch cover M10 nut frorque ct 20 20 Nim 065 4950 modb Allen wrench 5 mm T type 7 Install the clutch cover 3 screws M 6 torque at 8 10 Nm 70 90 in lb 4 3 GEAR TIMING SCHEMATIC In case of assembly of the gears which drive the balance shaft assembly must be performed following the timing schematic shown below A ATTENTION An uncorrect assembly of the gears can cause a malfunction in the vibration reduction system PISTON AT T D C CRANKSHAFT REF NOTCH BALANCE SHAFT REF NOTCH GEARS REF MARKINGS
37. starter cables Check and tighten the key to RUN position Bad grounding Check connections and tighten Interruption on fuse Replace 5 strip fuse after checking for eventual reversal of battery polarity Damaged cables Battery connection loose Check and tighten Battery discharged Recharge or replace battery Starter failure Overhaul starter Apply to Authorized Service Centers Electronic box or relay failure Check connectors Starter cranks but engine won t start Bad cable connections when turning the key in RUN Bad H T coil connections or coil Check replace failure position Bad H T coil grounding Check grounding Electronic box or ignition failure Apply to Authorized Service Centers Wet spark plug Malfunction on induction system fuel pipe on carburetor Check reed petals Replace if necessary Check stator connector Engine starts but it stops after a few Bad cable connections seconds when turning the key in RUN position Apply to Authorized Service Centers screw sect 3 3 engine is running Centers Rough idle Bad carb adjustement screw Check carburetor adjustment see sect 3 3 Drop in engine performance Check piston Bad carburetor adjustment Check carburetor adjustment see sect 3 3 Excessive wear of friction material Exhaust too noisy Check and replace if necessary MAN 043C 45 4 7 ENGINE PRESERVATION When engine is to r
38. th 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 043 28 3 11 SPARK PLUG AND THERMAL DECREE The engine is supplied with a standard BRTOEG spark plug which represents a good compromise between the needs of a good running 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 o
39. uggest 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 case the engine is stopped with the key RUN position fo restart if turn the key fo 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 fo the carb interrupt and try again atter 15 seconds Short and trequent 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 043 24 3 5 ENGINE RUNNING IN The running 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 Increase the speed for 5 minutes at 34 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
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