2003 IAME Parilla 125cc 125 Leopard TAG Engine Service & Repair Manual

ZZZHXURNDUWGH MAN-016 D 125cc LEOPARD TaG engine 2003 ASSEMBLY INSTRUCTIONS and USER MANUAL 18/10/02 mod. C ZZZHXURNDUWGH

ZZZHXURNDUWGH 18/10/02 mod. C MAN-016 D 1 INDEX GENERAL DESCRIPTION OF THE "LEOPARD" ENGINE CHARACTERISTICS OF THE "LEOPARD" ENGINE – OPERATIONAL LIMITS 1- Contents of the packing 2- Motor identification Number 3- Preparation and installation of the engine on the chassis 3.1 Install the water cooling system 3.2 Exhaust header assembly 3.3 Preparation and installation of the motor-mount 3.4 Install the carburetor 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 Page 1 2 3 4 5 5 9 9 10 12 13 14 15 18 19 20 21 22 22 22 23 23 25 26 27 28 31 32 33 34 35 ZZZHXURNDUWGH

ZZZHXURNDUWGH 18/10/02 mod. C MAN-016 D 1 GENERAL DESCRIPTION OF THE "LEOPARD" ENGINE This engine of the "TaG" series (Touch and Go) has been expressly designed and developed for the powering of karts for hobby racing on closed tracks, destined for this specific purpose. When designing this new line of engines, the technical solutions already adopted for the high performance engines were used, in order to guarantee the highest reliability of components, when the operating limitations are respected. 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; 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. ZZZHXURNDUWGH

ZZZHXURNDUWGH 18/10/02 mod. C MAN-016 D 2 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 • Max. water Temperature : 90°c ATTENTION: Never exceed the above limits, no obligation of IAME exists in case the above limits are exceeded. ZZZHXURNDUWGH

ZZZHXURNDUWGH 18/10/02 mod. C MAN-016 D 3 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 • 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 ZZZHXURNDUWGH

ZZZHXURNDUWGH 18/10/02 mod. C MAN-016 D 4 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 manufacturing processes and do not identify the motor. NOTE: In case of need for spares and when contacting the IAME Support Centers, please always refer to the Motor Identification Number and to the motor model. ZZZHXURNDUWGH

ZZZHXURNDUWGH 18/10/02 mod. C MAN-016 D 5 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) ALIGNING ITS RACES WITH THE DRIVEN PULLEY. TIGHTEN THE CLAMPS WITH TWO SCREWS M6 X 25. Fig.1 Fig.2 Fig.3 ZZZHXURNDUWGH

ZZZHXURNDUWGH 18/10/02 mod. C MAN-016 D 6 4 INSTALL THE BELTS AND TENSION (SEE FIG. 4). BEFORE INSTALLING THE RADIATOR PREASSEMBLE THE FOLLOWING COMPONENTS 5 INSERT THE RUBBER DAMPENERS INTO THE FIXING HOLES OF THE RADIATOR AND INSERT THE SPACERS (SEE FIG. 5). 6 INSERT THE BUSHES INTO THE RADIATOR SUPPORT BRACKET. PLACE THE BRACKET BETWEEN THE RADIATOR FIXINGS (SEE FIG. 6). Fig.4 Fig.5 RUBBER DAMPENER SPACER BUSH RADIATOR SUPPORT BRACKET Fig.6 ZZZHXURNDUWGH

ZZZHXURNDUWGH 18/10/02 mod. C MAN-016 D 7 7 FIX THE SUPPORT BRACKET TO THE RADIATOR, AND ALSO INSERT THE UPPER SUPPORT BRACKET (SCREWS M6X90 AND M6X85 WITH NUTS). PLACE THE RADIATOR LOWER FIXING CLAMP AND THE SPACER ON THE RADIATOR SUPPORT BRACKET (SCREW M8X45 WITH NUT) (SEE FIG. 7). 8 PLACE THE LOWER FIXING CLAMP ON THE CHASSIS SIDE RAIL (BRAKE SIDE) (N°2 SCREWS M8X45 WITH NUTS) TIGHTEN THE BOLTS BY HAND (SEE FIG. 8). 9 PLACE THE RADIATOR SO THAT THE HOLE, ON THE UPPER RADIATOR BRACKET, AND ONE OF THE UPPER HOLES ON THE BEARING SUPPORT BOX, MATCH (SEE FIG. 9). ONCE YOU FIND THE CORRECT POSITION, TIGHTEN ALL THE BOLTS 10 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 (SEE FIG.10). Fig.7 UPPER SUPPORT BRACKET RADIATOR LOWER FIXING CLAMP SPACER Fig.8 Fig.9 SCREW M6X90 SCREW M6X85 ZZZHXURNDUWGH

ZZZHXURNDUWGH 18/10/02 mod. C MAN-016 D 8 11 CONNECT THE SECOND HOSE BETWEEN THE FITTINGS ON THE RADIATOR OUTLET AND THE PUMP INLET. CONNECT THE THIRD HOSE BETWEEN THE FITTINGS ON THE PUMP OUTLET AND THE ENGINE INLET (SEE FIG. 10). TIGHTEN WITH STEEL CLAMPS. 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. Fig.10 ZZZHXURNDUWGH

2003 IAME Parilla 125cc 125 Leopard TAG Engine Service & Repair Manual

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