IAME Parilla Leopard K, Assembly Instructions & User Manual

Page 1: ...MAN 048 ING ISTRUZIONI DI MONTAGGIO DI UTILIZZO LEOPARD 125cc RL TaG K engine ASSEMBLY INSTRUCTIONS USER MANUAL ...

Page 2: ...l 3 8 Electrical connections 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 RPM limitation 9 Inlet silencer 10 Exhaust system 11 Centrifugal clutch 12 Instructions for the assembly disassembly of the clutch 13 Battery 14 Warnings on the electrical system 15 Spark plug and therm...

Page 3: ...r relay the H T coil a switch key assembly and the wiring harness with a 5A fuse which connects the whole system The electronic box which controls the advance the rev limitation and the engine start stop logic integrates the voltage regulator and the ignition circuit The starter relay Solid type SSR protected from short circuits supplies the power for the electric starter and is controlled by the ...

Page 4: ...perature 65 c ATTENTION Never exceed the above limits no obligation of IAME exists in case the above limits are exceeded 1 CONTENTS OF THE PACKING Each Leopard engine is supplied with the accessories under shown EXHAUST SYSTEM QuantitY Flexible 1 Spring for flexible 3 Exhaust fiber strip 1 Exhaust manifold 1 Exhaust muffler 1 INDUCTION Tillotson carburetor 1 Intake silencer 1 ELECTRICAL PLANT Batt...

Page 5: ...ITH SUPPORT INTAKE SILENCER TILLOTSON CARBURETOR ADDITIONAL ENGINE PLATE RADIATOR RADIATOR SUPPORT KIT WATER HOSE KIT COMPLETE PUMP GROUP NGK SPARK PLUG COMPLETE ELECTRIC ASSEMBLY EXHAUST SYSTEM CLUTCH COVER H T COIL STARTER BRUSHES KIT ...

Page 6: ...er 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 ...

Page 7: ...is it is at care of the assembler to follow these instructions The final customer in this case can skip this section and can start reading from section 4 Whenever the engine or a component is disassembled it is necessary to always follow the under shown instructions for proper reassembly 3 1 INSTALLATION SKETCH OF THE ENGINE ON THE CHASSIS ...

Page 8: ...32mm ASSEMBLE THE PUMP FIXING BRACKET ON THE CLAMP N 2 SCREWS M6x12 AND PLACE THE CLAMPS ON THE REAR CROSS RAIL N 2 SCREWS M6x25 INSTALL THE PUMP ON THE BRACKET 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 3 INSTALL ON THE AXLE THE DRIVING PULLEY N 2 CLAMPS AVAILABLE IN DIFFERENT DIAMETER...

Page 9: ...E THE FOLLOWING COMPONENTS 5 INSERT THE 4 RUBBER DAMPENERS INTO THE FIXING HOLES ON THE RADIATOR SEE FIG 5 6 PLACE THE RADIATOR SUPPORT BRACKET BETWEEN THE RADIATOR FIXINGS BY TILTING ONE END AND INSERTING IT THROUGH THE RUBBER DAMPENERS SEE FIG 6 NOTE OIL THE BRACKET ENDS AND THE DAMPENERS HOLES Fig 4 Fig 5 RUBBER DAMPENER RADIATOR SUPPORT BRACKET Fig 6 ...

Page 10: ...ET RADIATOR CAP SIDE N 1 SCREW M6x90 AND N 1 SCREW M6x85 WITH NUT INSTALL THE L SHAPE BRACKET ON THE LOWER RADIATOR CLAMP AVAILABLE IN DIFFERENT DIAMETERS Æ28 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 Fig 9 RADIATOR FIXING BRACKET LOWER FIXING CLAMP SCREW M6X90 SCREW M6X85 SCREW M6X12 SCREW M8X20 Fig 8 Fig 7 ...

Page 11: ...ND HOSE TO THE FITTINGS ON THE RADIATOR OUTLET AND THE PUMP INLET TIGHTEN WITH STEEL CLAMPS ON BOTH SIDES CONNECT THE THIRD HOSE TO THE FITTINGS ON THE PUMP OUTLET AND THE ENGINE INLET TIGHTEN WITH STEEL CLAMPS ON BOTH SIDES SEE FIG 12 BEFORE STARTING THE ENGINE FOLLOW THESE RECOMMENDATIONS Unscrew the cap on the radiator and loosen the breather plug on the engine head Fill the radiator until the ...

Page 12: ...E NUTS AND THE EXHAUST COVER 3 3 2 MAKE SURE THE EXHAUST GASKET IS IN SEAT AND INSTALL THE EXHAUST HEADER SEE FIG 1 3 3 3 INSTALL THE THREE WASHERS 3 3 4 INSTALL THE THREE NUTS TORQUE AT 9 11 Nm 80 100 in lb 12 POINT WRENCH 10 mm OR OPEN WRENCH 10 mm PREPARATION AND INSTALLATION OF THE MOTOR MOUNT NOTE ALL THE DIMENSIONS ARE IN MILLIMETERS 3 4 3 4 1 DRILL 4 HOLES DIAM 8 5mm IN THE MOTOR MOUNT Fig ...

Page 13: ...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 10 4 ALLEN SCREWS M8 TORQUE AT 22 24 Nm 190 210 in lb 6 mm ALLEN WRENCH INSTALL THE CARBURETOR 3 5 3 5 1 INSTALL THE GAS CABLE CLAMP ON THE SUPPORT SEE FIG 4 12 POINT WRENCH 10mm Fig 2 Fig 3 Fig 4 ...

Page 14: ...T AND THE TWO SCREWS SEE FIG 6 3 5 4 INSTALL THE INTAKE SUPPORT 2 SCREWS M5 X10 SEE FIG 7 ALLEN WRENCH 3 mm 3 5 5 INSTALL THE CARBURETOR SEE FIG 8 9 REMOVE THE TWO M6 NUTS FROM THE INLET MANIFOLD REMOVE THE PLASTIC PLUG FROM THE INLET MANIFOLD ATTENTION MAKE SURE THAT THE PRESSURE HOLE ON THE GASKET IS NOT PLUGGED 10 mm OPEN WRENCH Fig 5 Fig 6 Fig 7 Fig 8 ...

Page 15: ...M6 AND TWO WASHERS TORQUE AT 6 10 Nm 50 90 in lb 3 6 INSTALL THE ENGINE ON THE CHASSIS 3 6 1 POSITION THE ENGINE ON THE 2 OUTSIDE MAIN RAILS AND FIX THE MOTOR MOUNT WITH THE TWO CLAMPS SEE FIG 10 SUGGESTION NEVER TORQUE COMPLETELY THE CLAMPS UNTIL THE CHAIN IS INSTALLED AND PROPERLY ALIGNED 3 6 2 CHECK THE ALIGNMENT OF THE ENGINE SPROCKET AND THE AXLE SPROCKET WITH A STRAIGHT EDGE SEE FIG 11 3 6 3...

Page 16: ... 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 COU...

Page 17: ...NE BOLT DEPENDING ON THE TYPE OF CHASSIS NOTE THE BOX AND CLAMPS ARE PROVIDED WITH VARIOUS HOLES WHICH ALLOW INSTALLATION ON ALL KIND OF CHASSIS 10mm BOX WRENCH 3 8 3 INSERT THE BATTERY IN THE BOX AND FASTEN WITH THE BATTERY STRAP SEE FIG 18 POSITION THE BATTERY TERMINALS AS SHOWN ON THE FIGURE ATTENTION PAY ATTENTION NOT TO SHORT CIRCUIT THE BATTERY TERMINALS AS THE BATTERY COULD BE DAMAGED BEYON...

Page 18: ...HARNESS SEE FIG 21 ATTENTION MAKE SURE THAT THE FIXING TONGUES ARE PROPERLY INSERTED TO GUARANTEE THE BEST POSSIBLE CONNECTION OF THE TERMINALS 3 8 6 CHECK THE ELECTRIC STARTER CABLE FIXING SEE FIG 22 AND COMPLETE THE FIXING OF THE HARNESS SEE FIG 23 ATTENTION NEVER LET THE HARNESS GET IN TOUCH WITH THE GROUND OR WITH A ROTATING PART AS IT COULD BE DAMAGED BEYOND REPAIR Fig 20 Fig 21 Fig 23 Fig 22...

Page 19: ...EYELET TERMINAL Ø 7mm OF THE SECOND GROUND CABLE IN THE HARNESS CLOSE TO THE COIL CABLE TO THE H T COIL BY MEANS OF THE M6 NUT FIXING THE COIL SEE FIG 25 TORQUE AT 8 10 Nm 70 90 in lb ATTENTION THIS OPERATION IS EXTREMELY IMPORTANT AS AN UNCERTAIN GROUNDING COULD DAMAGE THE POWER PACK BEYOND REPAIR 10mm BOX WRENCH 3 8 9 CONNECT THE H T COIL CABLE TO THE HARNESS TERMINAL SEE FIG 26 ATTENTION FASTEN...

Page 20: ...ECT THE STARTER RELAY TO THE 4 POLE TERMINAL IN THE WIRING HARNESS SEE FIG 30 ATTENTION MAKE SURE THAT THE FIXING TONGUES ARE PROPERLY INSERTED TO GUARANTEE THE BEST POSSIBLE CONNECTION OF THE TERMINALS 3 8 12 DRILL A Ø 22mm HOLE IN THE SIDE OF FRONT FAIRING ENGINE SIDE AND INSERT THE STARTING ASSEMBLY SEE FIG 31 SECURE THE ASSEMBLY WITH THE THREADED RING NUT Fig 28 ELECTRONIC BOX RELAY FUSE HOLDE...

Page 21: ...IC BOX AND THE STARTER RELAY SEE FIG 33 NOTE CLEAN AND DEGREASE THE FAIRING FIXING SURFACE WHERE THE STRAP IS TO BE PLACED TO GUARANTEE THE BEST POSSIBLE STRAP ATTACHMENT 3 8 15 DRILL A FEW HOLES IN THE FAIRING TO ATTACH THE CABLES WITH PLASTIC CLAMPS SEE FIG 34 3 8 16 ATTACH THE DUAL LOCK FIXING STRAP UNDER THE FRONT FAIRING CLOSE TO THE BATTERY AND PLACE THE FUSE HOLDER SEE FIG 35 NOTE CLEAN AND...

Page 22: ... THE TERMINALS 3 8 18 SCREW THE SPARK CAP ON THE H T COIL SEE FIG 37 3 8 19 FIX THE CAP TO THE H T CABLE WITH A PLASTIC CLAMP SEE FIG 38 INSTALL THE SPARK PLUG TORQUE AT 20 26 Nm 175 230 in lb INSTALL THE CAP ON 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 CHAS...

Page 23: ...INSTALL THE FLEXIBLE L 65mm FLEXIBLE COMPLETELY CLOSED AND THE EXHAUST HEADER SEE FIG 40 AND FIT THE INSULATING SLEEVE ON THE FLEXIBLE SEE FIG 41 3 10 2 INSERT THE FLEXIBLE ON THE EXHAUST HEADER AND FIX WITH THE 3 SPRINGS SEE FIG 42 THE ENGINE IS READY TO BE STARTED Fig 40 Fig 41 Fig 39 INSULATING SLEEVE FLEXIBLE Fig 42 ...

Page 24: ...ston and the head Our experience dictates use of oils such as SHELL ADVANCE RACING M ELF HTX 909 ERG K KART 2T CORSE ERG K KART FORMULA Once the fuel tank is filled make sure that gasoline reaches the carburetor before starting the engine Never use the electric starter to suck the gasoline as this would discharge the battery SUGGESTION Disconnect the plastic tube on the carb and the vent tube on t...

Page 25: ... further 1 T O after contact with throttle lever Start the engine and warm it If RPM 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 ...

Page 26: ...on 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 1500 RPM C When the engine is running the key can be left both in the RUN or KEY position We suggest for pratical reasons to turn the key to KEY position this allows with a single tripping to stop the engine STOP position or to rest...

Page 27: ...k the torque of the exhaust header nuts as during the break in the nuts tend to become loose refer to the attached table 8 RPM LIMITATION The electronic box incorporates an RPM limiter which prevents the engine from exceeding 17000 RPM This limit cannot be exceeded otherwise the engine could be damaged by the extremely high RPM ATTENTION Do not keep the engine for a long time at the RPM at which t...

Page 28: ...er 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 th...

Page 29: ...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 ...

Page 30: ...iston 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 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 12 point wrench 19...

Page 31: ...sher 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 at 8 10 Nm 70 90 in lb 13 BATTERY The battery 12 V 9 Ah is sealed and without maintenance In order to lengthen the battery life it is ...

Page 32: ...the engine ATTENTION If these prescriptions are not followed the electrical system and the engine could be damaged beyond repair No obligation of IAME exists in this case 1 Please turn the key to STOP position every time the engine is stopped If the key is left in KEY position for a long time even if the engine is stopped the battery would be discharged completely 2 Never disconnect the ground cab...

Page 33: ...iginal electric system might cause malfunctions No obligation of IAME exists in this case 15 SPARK PLUG AND THERMAL DEGREE The engine is supplied with a standard NGK BR10EG spark plug which represents a good compromise between the needs of a good break in and the racing needs in normal conditions Use of different spark plugs is possible and as a general information we are attaching a correspondenc...

Page 34: ...manufacturer the wears and stress of the various components con rods roller cages bearings etc will be such as to drastically reduce the life of the engine itself It is therefore extremely important that the user respects the operating limits imposed by the manufacturer The operating limit for the Leopard engine is 17000 RPM and the RPM limiter is calibrated at this value ATTENTION Never exceed th...

Page 35: ... 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 ...

Page 36: ...MAN 048 ING 34 SPROCKET RATIO TO ACHIEVE MAX 16500 RPM Sprocket ratio Engine Max RPM during tests ...

Page 37: ...EMBLE THE STARTER UNLOOSE THE SCREW M6X30 ON THE STARTER SUPPORT see Fig 1 5mm ALLEN WRENCH T TYPE REMOVE THE STARTER SUPPORT 3 SCREWS M6X25 see Fig 2 5mm ALLEN WRENCH T TYPE UNSCREW N 3 SCREWS M6x35 see Fig 3 5mm ALLEN WRENCH T TYPE REMOVE STARTER see Fig 4 Fig 1 Fig 2 Fig 3 Fig 4 ...

Page 38: ... 048 ING 36 2 OPENING THE STARTER REMOVE THE PLASTIC CLAMP AND UNSCREW THE SCREW M4 FIXING THE INPUT CABLE TO THE STARTER see Fig 5 SCREWDRIVER UNSCREW 3 SCREWS M5 C see Fig 6 SCREWDRIVER Fig 1 Fig 5 Fig 6 ...

Page 39: ...OR FROM STARTER HEAD see Fig 8 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 9 SCREWDRIVER REMOVE THE LITTLE RUBBER CAP F see Fig 10 PLIERS OUR SUGGESTION SLIGHTLY OIL THE TIN PLATE TERMINAL END TO MAKE EASIER THE EXTRACTION OF THE LITTLE RUBBER CAP Fig 4 Fig 7 Fig 8 Fig 9 Fig 10 ...

Page 40: ...E SPRINGS MAKING PRESSURE EXTERNALLY ON THE TIN PLATE TERMINAL REMOVE BRUSH see Fig 12 INSTALL NEW BRUSH TERMINAL INSIDE see Fig 13 PLACE LITTLE RUBBER CAP ON THE TERMINAL REINSTALL THE PLATE AND FIXE IT WITH THE 2 SCREWS M4 see Fig 14 SCREWDRIVER Fig 9 Fig 11 Fig 12 Fig 13 Fig 14 ...

Page 41: ...SH 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 see Fig 16 INSTALL THE STARTER ROTOR BETWEEN THE BRUSHES AND CHECK THAT THEY ARE ALWAYS IN CONTACT WITH THE CYLINDRIC COPPER PART OF THE ROTOR EVEN WHEN THEY ARE RELEASED see Fig 17 OUR SUGGESTION TO IMPROVE THE BRUSHES LIFE SECURE THE LITTLE WIRES WITH SILICONE ...

Page 42: ...OF THEIR SEAT see Fig 19 SCREW THE 3 SCREWS M5 see Fig 20 SCREWDRIVER CHECK THAT THE STARTER ROTOR ROTATES FREELY CONNECT THE INPUT WIRING TO THE STARTER WITH THE SCREW M4 see Fig 21 SCREWDRIVER ASSEMBLING THE STARTER PLACE THE STARTER IN SEAT see Fig 22 OIL O RING TO MAKE EASIER INSTALLATION N 3 SCREWS TCH M6x35 TIGHTEN AT A 8 10 Nm 70 90 in lb 5mm WRENCH T TYPE Fig 19 Fig 20 Fig 21 Fig 22 ...

Page 43: ...n Battery Check status and charge Cables and connectors Check status and connections Grounding of engine and electronic box 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 ...

Page 44: ...ction system Check status and connection on fuel pipe Replace gaskets and membranes on carburetor Check reed petals Replace if necessary Engine starts but it stops after a few seconds when turning the key in RUN position Bad cable connections Check stator connector Electronic box or starter failure Apply to Authorized Service Centers Bad carburetor adjustment I screw Check carburetor adjustment se...

Page 45: ...ved as follows Disconnect the battery and charge it periodically see Sect 12 Disconnect carburetor and clean it Seal with tape the engine inlet and exhaust The external of the engine must be cleaned Spray with protective oil the steel parts subject to oxidation Keep the engine in a dry ambient 21 TORQUE VALUES ...

Page 46: ...MAN 048 ING 44 ...