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- 125cc LEOPARD TaG
- Assembly Instructions And User's Manual
IAME 125cc LEOPARD TaG Assembly Instructions And User's Manual
Summary of 125cc LEOPARD TaG
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Man-016 d 125cc leopard tag engine 2003 assembly instructions and user manual 18/10/02 mod. C.
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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 e...
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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, t...
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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 ?? Lubric...
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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 ?? ...
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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 specia...
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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 f...
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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...
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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 clam...
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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...
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18/10/02 mod. C man-016 d 9 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 ...
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18/10/02 mod. C man-016 d 10 3.3.2 before installing the motor mount, position the additional mount plate on the crankcase (see fig. 2). 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 ...
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18/10/02 mod. C man-016 d 11 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...
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18/10/02 mod. C man-016 d 12 attention: when replacing the carb gasket always make sure that the gasket is installed so that the hole in the gasket matches with the two pressure holes in the carb. And in the crankcase: otherwise the engine won’t start. Install the carburetor. N.2 nuts m6 and two was...
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18/10/02 mod. C man-016 d 13 3.5.4 move the engine on the rails and optimize the chain tension . Attention: the play of the chain must be appr. 15mm (½÷¾ inch) measured in the shown point (see fig. 13) 3.5.5 torque the clamp screws install the clutch cover with h.T. Coil 3.6 3.6.1 remove the 3 screw...
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18/10/02 mod. C man-016 d 14 electrical connection (refer 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 inst...
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18/10/02 mod. C man-016 d 15 3.7.4 insert the battery strap (see fig. 19). 3.7.5 insert the battery with terminals towards the outside (see fig. 20). Suggestion: never connect the battery until you are ready to start the engine. Seal the battery terminals with plastic tape to avoid that eventual vib...
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18/10/02 mod. C man-016 d 16 3.8.3 fix the ground cable, from the power-pack, on the engine carter, by means of the proper threaded hole (see fig. 22). Attention: this operation is extremely important as an uncertain grounding could damage the power pack box beyond repair. 3.8.4 connect the terminal...
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18/10/02 mod. C man-016 d 17 3.8.6 chek the electric starter cable fixing (see fig. 26) and complete the fixing of the harness (see fig. 27). Attention : never let the harness get in touch with the ground or with a rotating part as it could be damaged beyond repair. 3.8.7 connect the coil cable from...
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18/10/02 mod. C man-016 d 18 3.8.9 insert the spark plug cap on the spring (see fig. 30). 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 ...
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18/10/02 mod. C man-016 d 19 3.10 install the exhaust note: 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. 33) and connect the exhaust. 3.10.2 install the fiber strip around the...
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18/10/02 mod. C 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. As on the other hand, use of castor oils creates gummy residues which g...
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18/10/02 mod. C man-016 d 21 5- carburetor adjustment guide 1 t.O. * rich lean 1 ¼ t.O. ¾ t.O. 1 ½ 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 ¼ ÷ 1 ½ t.O. ?? H (close the screw completely and then o...
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18/10/02 mod. C 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 en...
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18/10/02 mod. C 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 ...
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18/10/02 mod. C 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...
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18/10/02 mod. C 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 serv...
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18/10/02 mod. C 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) atte...
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18/10/02 mod. C 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, plas...
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18/10/02 mod. C 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 ...
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18/10/02 mod. C 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 8,30 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 ...
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18/10/02 mod. C 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 che...
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18/10/02 mod. C 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 tight...
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18/10/02 mod. C 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 ext...
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18/10/02 mod. C man-016 d 34.
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18/10/02 mod. C man-016 d 35.
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18/10/02 mod. C man-016 d 36 assembly instructions & user manual ? 2001 by iame joint stock comp. 1 st edition , november 2000 all rights reserved. Any reprinting or unauthorized use without the written permission of iame joint stock comp. Is expressly prohibited wiring diagram.