LEOPARD USA MY’09 125cc - RL - TaG

ASSEMBLY INSTRUCTIONS
&
USER MANUAL

16/05/2011 MAN-055A
 INDEX PAGE

GENERAL DESCRIPTION OF THE ENGINE 1

LEOPARD MY'09 ENGINE CHARACTERISTICS – OPERATIONAL LIMITS 2

Contents of packing 2

Engine serial number 4

Preparation and installation of the engine on the chassis 5

3.1 Installation sketch of the engine on the chassis 5
3.2 Install the water-cooling system 6
3.3 Exhaust header assembly 10
3.4 Preparation and installation of the motor mount 10
3.5 Install the carburettor 11
3.6 Install the engine on the chassis 13
3.7 Install the clutch cover with H.T. coil 14
3.8 Electric connections 15
3.9 Installation of the intake silencer 20
3.10 Install the exhaust system 21

4- Gasoline and Oil 22

5- Carburettor adjustment guide 23

6- Starting and stopping the engine 24

7- Engine break-in 25

8- RPM limiter 25

9- Intake silencer 25

10- Recommendations on the exhaust system 26

11- Centrifugal clutch 27

12- Instructions for the disassembly / reassembly of the clutch 28

13- Battery 29

14- Warnings on the electrical system 30

15- Sparkplug and thermal degrees 31

16- Choice of the best sprocket ratio 32

17- Replacement of the starter brushes 35

18- Scheduled maintenance 41

19- Troubleshooting 42

20- Engine and accessories preservation 43

21- Fastener torque table 43

wiring diagram 44

MAN-055A
 GENERAL DESCRIPTION OF THE 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 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
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 17.000
RPM during use.
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 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 carburettor is a diaphragm Tillotson carburettor (Tillotson HL series) with integral fuel
pump, filter and all position mounting capability.
The battery (12 V - 9Ah) is a sealed, no maintenance battery and is supplied already
preassembled, in the battery 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.

1 MAN-055A
 CHARACTERISTICS OF THE "LEOPARD" ENGINE – OPERATIONAL LIMITS

The characteristics of the engine are the following :

• Cycle: OTTO / 2 stroke
• Original cubic capacity: 123.67 cc
• Original bore : 54.00 mm
• Max. theoretical bore: 54.28 mm
• Stroke : 54.00 mm
• Lubrification : Fuel / oil mix. 6% (16.1)
• Induction : Reed valve
• Carburettor: Membrane, Tillotson
• Cooling : Water
• Ignition : Digital / with integral rev. limiter
• Battery charge: With integral generator
• Electric start : 12V/0.30 Kw
• Clutch : Automatic ,dry, centrifugal
Operational limits :
• Max. RPM: 17.000 RPM (with rev. limiter)
• Min. water temperature: 45°c
• Max.water temperature: 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 125 MY '09 engine is supplied with the under shown accessories:
EXHAUST SYSTEM Quantity
• Flexible 1
• Spring for flexible 3
• Exhaust fiber strip 1
• Exhaust manifold 1
• Exhaust muffler 1
INDUCTION
• Tillotson carb. 1
• Intake silencer 1
ELECTRICAL PLANT
• 12 V Battery – 9Ah 1
• Battery support 1
• Battery strip 1
• Battery fixing clamps 2
• Electronic box 1
• Starter relay 1
• H.T. coil 1
• Starting key assembly 1
• Fixing clamps 8
• NGK BR 10 EG spark plug 1
• Spark plug cap 1
MISCELLANEOUS
• Clutch cover with coil 1
• Starter brushes kit (refill) 1
• Dual-Lock fixing strap 1
WATER COOLING SYSTEM
• Radiator 1
• Radiator support kit 1
• Water hose k it 1
• Complete pump group 1

2 MAN-055A
 ACCESSORIES

EXHAUST SYSTEM BATTERY WITH SUPPORT NGK SPARK PLUG

CLUTCH COVER / H.T. COIL

COMPLETE ELECTRIC ASSEMBLY

ADDITIONAL ENGINE PLATE STARTER BRUSHES KIT INTAKE SILENCER

TILLOTSON CARBURETTOR RADIATOR SUPPORT KIT COMPLETE PUMP GROUP

WATER HOSE KIT RADIATOR

3 MAN-055A
2- MOTOR IDENTIFICATION NUMBER

The official motor identification number can be found stamped in the front right 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.

4 MAN-055A
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- INSTALLATION SKETCH OF THE ENGINE ON THE CHASSIS

5 MAN-055A
3.2- INSTALL THE WATER COOLING SYSTEM

NOTE:
To install the water pump belts it is necessary to remove the rear axle.

REINSTALL THE REAR AXLE AFTER

1 HAVING INSERTED TWO BELTS Fig.1
SUGGESTION:
INSTALL OTHER TWO BELTS AS SPARES
AND FIX THEM WITH TAPE TO THE AXLE.

INSTALL THE WATER PUMP (1 SCREW

2 M8x45 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 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
PUMP FIX. BRACKET
THE ALIGNMENT AND TENSIONING OF THE
BELTS.
VITE M8X45

VITE M6X12

Fig.2
SCREW M6X25

INSTALL ON THE AXLE THE DRIVING

3 PULLEY (N° 2 CLAMPS AVAILABLE IN
DIFFERENT DIAMETERS ∅30/35/40/50mm)
ALIGNING ITS RACE WITH THE DRIVEN
PULLEY (SEE FIG.3).
FIX THE TWO CLAMPS WITH 2 SCREWS
M5x22 (TIGHTEN AT 6÷ 8 Nm) (50÷70 in-lb).
TIGHTEN THE TWO SCREWS M6x25 ON
THE PUMP FIXING CLAMPS AND THE
SCREWS M6x12 ON THE PUMP FIXING
BRACKET. SCREW M5X22
TIGHTEN AT 8÷10 Nm (70÷90 in-lb)

Fig.3

6 MAN-055A
 INSTALL THE BELTS AND TENSION (SEE
4 FIG. 4).
TIGHTEN THE SCREW M8x45
TORQUE AT 18÷22 Nm (160÷190 in-lb)

Fig.4

BEFORE INSTALLING THE RADIATOR PREASSEMBLE THE FOLLOWING COMPONENTS

INSERT THE 4 RUBBER DAMPENERS INTO

5 THE FIXING HOLES ON THE RADIATOR
(SEE FIG. 5). RUBBER DAMPENER

Fig.5

- PLACE THE RADIATOR SUPPORT

6 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
RUBBER DAMPENER HOLES TO
FACILITATE INSERTION.

RADIATOR SUPPORT
BRACKET

Fig.6

7 MAN-055A
 - COMPLETE INSERTION OF THE RADIATOR
SUPPORT BRACKET INTO THE RUBBER
DAMPENERS (SEE FIG. 7 AND 8).

Fig.7

Fig.8

FIX THE RADIATOR SUPPORT BRACKET

7 INSERTING ALSO THE RADIATOR FIXING
BRACKET (RADIATOR CAP SIDE – N°1
SCREW M6x90 AND N°1 SCREW M6x85 RADIAT. FIXING BRACKET
WITH NUT).
INSTALL THE “L” SHAPE BRACKET ON THE VITE M6X90
LOWER RADIATOR CLAMP (AVAILABLE IN
DIFFERENT DIAMETERS ∅28/30/32mm - 2
SCREWS M6x12) AND FIX IT TO THE VITI M6X12
TONGUE ON THE RADIATOR SUPPORT
BRACKET (N°1 SCREW M8x20 WITH NUT - VITE M8X20
SEE FIG. 9).

VITE M6X85

LOWER FIXING CLAMP

Fig.9

8 MAN-055A
 PLACE THE RADIATOR FIXING CLAMP ON
8 THE CHASSIS SIDE RAIL (BRAKE SIDE)
(N°2 SCREWS M6x25). TIGHTEN THE BOLTS
BY HAND (SEE FIG. 10).

Fig.10

PLACE THE RADIATOR SO THAT THE HOLE

9 ON THE RADIATOR BRACKET AND ONE OF
THE UPPER HOLES ON THE BEARING
SUPPORT BOX, MATCH. (N°1 SCREW M8) –
(SEE FIG. 11).
ONCE YOU FIND THE CORRECT POSITION
TIGHTEN THE M6x25 SCREWS ON THE
CLAMP. TORQUE AT 8÷10 Nm (70÷90 in-lb)

Fig.11

THE KIT INCLUDES THREE RUBBER

10 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.
- 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. 12).

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 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.

9 MAN-055A
3.3 EXHAUST HEADER ASSEMBLY
NOTE:
THE ENGINE IS SUPPLIED WITH THE EXHAUST GASKET AND NUTS ALREADY INSERTED. WHEN THE SHIPMENT IS MADE
AN EXHAUST CARD BOARD COVER GASKET IS PROVIDED TO PROTECT THE INTERNAL PARTS.

3.3.1 REMOVE THE NUTS AND THE EXHAUST

CARD BOARD COVER.

3.3.2 MAKE SURE THE EXHAUST GASKET IS Fig.1

IN SEAT AND INSTALL THE EXHAUST HEADER
(SEE FIG 1).

3.3.3. INSERT THE 3 WASHERS 6mm.

3.3.4 INSTALL THE THREE NUTS. 12 POINT WRENCH 10 mm (OR OPEN WRENCH 10 mm)
TORQUE AT 9 ÷ 11 Nm (80 ÷ 100 in-lb)

3.4 PREPARATION AND INSTALLATION OF THE MOTOR-MOUNT

NOTE: ALL THE DIMENSIONS ARE IN MILLIMETERS

3.4.1 DRILL 4 HOLES (DIAM. 8.5mm) IN THE MOTOR-MOUNT.

MOTOR-MOUNT PLANT VIEW

10 MAN-055A
 3.4.2 BEFORE INSTALLING THE MOTOR-MOUNT,
POSITION THE ADDITIONAL MOUNT PLATE ON
THE CRANKCASE (SEE FIG. 2)

Fig.2

3.4.3 INSTALL THE MOTOR MOUNT. MAKE SURE

Fig.3
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. 10)

4 ALLEN SCREWS M8 – TORQUE AT 22÷24 Nm

(190 ÷ 210 in-lb)

(6 mm ALLEN WRENCH)

3.5 INSTALL THE CARBURETTOR

3.5.1 INSTALL THE GAS CABLE CLAMP ON THE Fig.4

SUPPORT (SEE FIG. 4)

(12 POINT WRENCH 10mm)

11 MAN-055A
3.5.2 REMOVE 2 SCREWS 3.5mm ON THE CARB. Fig.5
PUMP (IN CORRESPONDENCE OF THE
THROTTLE LEVER) (SEE FIG. 5).

(SCREWDRIVER 4.8 mm)

3.5.3 INSERT THE GAS BRACKET AND THE TWO Fig.6

SCREWS (SEE FIG. 6).

3.5.4 INSTALL THE INTAKE SILENCER SUPPORT Fig.7

2 SCREWS M5 X10 (SEE FIG. 7)

(ALLEN WRENCH 3 mm)

3.5.5 INSTALL THE CARBURETTOR

(SEE FIG. 8 / 9).

ƒ REMOVE THE TWO M6 NUTS FROM THE

INLET MANIFOLD.
ƒ REMOVE THE PLASTIC PLUG FROM
THE INLET MANIFOLD

(10mm OPEN WRENCH)

ATTENTION:
MAKE SURE THAT THE PRESSURE HOLE ON
THE GASKET IS NOT PLUGGED .

Fig.8

12 MAN-055A
 ATTENTION: Fig.9
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 CARBURETTOR.

N.2 NUTS M6 AND TWO WASHERS.
TORQUE AT 6 ÷ 10 Nm (50 ÷ 90 in-lb)

BEFORE GOING AHEAD WITH THE OPERATIONS Fig.9 A

DISASSEMBLE THE CLUTCH COVER WITH H.T.
COIL BY REMOVING THE 3 SCREWS M6x30 ON
THE CRANKCASE .
(SEE FIG.10)

(ALLEN WRENCH 5mm)

Fig.10
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.

Fig.11

3.6.2 CHECK THE ALIGNMENT OF THE ENGINE Fig.12

SPROCKET AND THE AXLE SPROCKET WITH A
STRAIGHT EDGE .
(SEE FIG.12)

3.6.3 INSTALL THE CHAIN (PITCH: 7.775) .

(SEE FIG.13)

Fig.13

13 MAN-055A
 3.6.4 MOVE THE ENGINE ON THE RAILS TO
OPTIMIZE THE CHAIN TENSION .

ATTENTION:
THE PLAY OF THE CHAIN MUST BE APPR. 16mm
(1/2 ÷ 3/4 inch) MEASURED IN THE SHOWN
POINT
(SEE FIG. 14)

15mm

Fig.14

3.6.5 TORQUE THE CLAMP SCREWS

3.7 INSTALL THE CLUTCH COVER WITH

H.T. COIL
3.7.1 INSTALL THE CLUTCH COVER WITH H.T.
COIL
(SEE FIG.15).

TORQUE THE 3 SCREWS AT 8 ÷ 10 Nm

(70 ÷ 90 in-lb)

(ALLEN WRENCH 5 mm)

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 Fig.15
DAMAGE THE COIL BEYOND REPAIR.

14 MAN-055A
3.8
ELECTRICAL CONNECTIONS Fig.16
(refer to the attached electrical
schematic)
NOTE:
FOR A PROPER INSTALLATION FOLLOW THE
UNDER SHOWN INSTRUCTIONS

3.8.1 INSERT THE BATTERY STRAP IN THE

BATTERY SUPPORT (SEE FIG.16)

3.8.2 PLACE THE BATTERY SUPPORT BOX IN

THE FRONT OF THE CHASSIS (UNDER THE
FRONT FAIRING) AND FIX IT WITH THE CLAMPS
TO THE LOWER STEERING COLUMN SUPPORT
TUBES (M6x25 SCREWS– SEE FIG. 17).

(1Omm SOCKET WRENCH)

TORQUE AT 8 ÷ 10 Nm (70÷ 90 in-lb)
THE SUPPORT BOX MUST BE FIXED WITH AT
LEAST ONE BOLT FOR EACH CLAMP. FIX THE
BOX WITH MORE THAN ONE BOLT DEPENDING
ON THE TYPE OF CHASSIS.

NOTE:
THE BOX AND THE CLAMPS ARE PROVIDED
WITH VARIOUS HOLES WHICH ALLOW
INSTALLATION ON ALL KIND OF CHASSIS.
Fig.17

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 BEYOND REPAIR.

Fig.18

3.8.4 POSITION THE WIRING HARNESS

STARTING FROM THE ENGINE AND ALONG THE
RAIL, THE STEERING COLUMN AND UNDER THE
FRONT PANEL FAIRING (SEE FIG. 19).
TIGHTEN WITH PLASTIC CLAMPS.

ATTENTION:
NEVER LET THE HARNESS GET IN TOUCH WITH
THE GROUND OR WITH ROTATING PARTS AS IT
COULD BE DAMAGED BEYOND REPAIR.

Fig.19

15 MAN-055A
3.8.5 CONNECT THE TERMINAL FROM THE
IGNITION WITH THE 8 POLE TERMINAL ON THE Fig.20
HARNESS .
(SEE FIG. 20)

CONNECT THE ONE WAY TERMINAL FROM THE

ELECTRIC STARTER WITH THE ONE WAY
TERMINAL ON THE HARNESS
(SEE FIG. 21).

ATTENTION:
MAKE SURE THAT THE FIXING TONGUES ARE
PROPERLY INSERTED TO GUARANTEE THE
BEST POSSIBLE CONNECTION OF THE
TERMINALS .

Fig.21

3.8.6 CHECK THE ELECTRIC STARTER FIXING Fig.22

(SEE FIG. 22).

FIX THE HARNESS EYELET GROUND CABLE Fig.23

WITH THE EYELET TERMINAL TO THE STARTER
SUPPORT, BY MEANS OF THE FIXING SCREW
M6x35 (SEE FIG. 23).

(ALLEN SCREW 5 mm)

TORQUE AT 8 ÷ 10 Nm (70 ÷ 90 in-lb)

ATTENTION:
THIS OPERATION IS EXTREMELY IMPORTANT
AS AN UNCERTAIN GROUNDING COULD
DAMAGE THE ELECTRONIC BOX BEYOND
REPAIR.

16 MAN-055A
3.8.7 COMPLETE THE FIXATION OF THE
HARNESS (SEE FIG. 24).

ATTENTION:
NEVER LET THE HARNESS GET IN TOUCH WITH
THE GROUND OR WITH A ROTATING PART AS IT
COULD BE DAMAGED BEYOND REPAIR

Fig.24

3.8.8 FIX THE SECOND HARNESS GROUND

CABLE WITH THE EYELET TERMINAL (Ø 6.5mm), Fig.25
TO THE H.T. COIL, BY MEANS OF THE M6 NUT
(SEE FIG. 25).

(ALLEN SCREW 5mm)

TORQUE AT 8 ÷ 10 Nm (70 ÷ 90 in-lb)

ATTENTION:
THIS OPERATION IS EXTREMELY IMPORTANT
AS AN UNCERTAIN GROUNDING COULD
DAMAGE THE ELECTRONIC BOX BEYOND
REPAIR.

3.8.9 CONNECT THE H.T. COIL CABLE TO THE

HARNESS TERMINAL (SEE FIG. 26).

ATTENTION:
FASTEN THE COIL CABLE WITH A PLASTIC
CLAMP TO AVOID THAT EVENTUAL VIBRATIONS
MIGHT DISCONNECT THE TERMINALS (SEE FIG.
27).

Fig.26

Fig.27

17 MAN-055A
 FUSE HOLDER
3.8.10 CUT THE DUAL-LOCK FIXING STRAP AND
ATTACH IT TO THE ELECTRONIC BOX, THE
STARTER FUSE, AND THE FUSE HOLDER (SEE
FIG.28).

ELECTR. BOX
RELAY

Fig.28

3.8.11 CONNECT THE ELECTRONIC BOX TO THE

20 POLE TERMINAL IN THE WIRING HARNESS
(SEE FIG. 29).

CONNECT 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 . Fig.29

Fig.30

3.8.12 DRILL A Ø22mm 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.

Ø 22mm

Fig.31

18 MAN-055A
3.8.13 CONNECT THE CABLE FROM THE Fig.32
STARTING ASSEMBLY WITH THE 8 POLE
TERMINAL IN THE WIRING HARNESS (SEE FIG.
32).

ATTENTION:
MAKE SURE THAT THE FIXING TONGUES ARE
PROPERLY INSERTED TO GUARANTEE THE
BEST POSSIBLE CONNECTION OF THE
TERMINALS .

3.8.14 ATTACH THE DUAL LOCK FIXING STRAP

UNDER THE FRONT FAIRING (CLOSE TO THE Fig.33
STEERING COLUMN) AND PLACE THE
ELECTRONIC 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).

Fig.34

3.8.16 ATTACH THE DUAL LOCK FIXING STRAP Fig.35

UNDER THE FRONT FAIRING (CLOSE TO THE
BATTERY) AND PLACE THE FUSE HOLDER (SEE
FIG. 35).

NOTE:
CLEAN AND DEGREASE THE FAIRING FIXING
SURFACE WHERE THE STRAP IS TO BE
PLACED TO GUARANTEE THE BEST POSSIBLE
STRAP ATTACHMENT.

19 MAN-055A
 3.8.17 PLACE THE WIRING HARNESS BATTERY
TERMINALS UNDER THE BATTERY STRAP (SEE
FIG. 36).

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.

Fig.36

3.8.18 SCREW THE SPARK CAP ON THE H.T.COIL Fig.37

CABLE (SEE fig. 37).

3.8.19 FIX THE CAP TO THE H.T. CABLE WITH A Fig.38

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 Fig.39

-MAKE SURE THAT THE FILTER HAS THE INLET

HOLES TOWARDS THE UPPER SIDE AND THAT
THE HOLES ARE NOT PLUGGED.

-FIX THE FILTER ON THE CARB. WITH A STEEL

CLAMP AND THE FILTER TO THE CHASSIS SIDE
RAILS WITH PLASTIC CLAMPS (SEE FIG. 39 / 40).

Fig.40

20 MAN-055A

Fig.32
3.11 INSTALL THE EXHAUST

NOTE:
SEE SECTION 9 FOR THE RECOMMENDATIONS
ON THE IDEAL EXHAUST LENGHT

3.11.1 INSTALL THE FLEXIBLE (L= 60mm Fig.41

FLEXIBLE COMPLETELY CLOSED) ON THE
EXHAUST HEADER (SEE FIG. 41) AND ASSEMBLE
THE EXHAUST MUFFLER.

3.11.2 WIND THE STRAP IN REFRACTORY

MATERIAL ROUND THE FLEXIBLE AND FIX IT
Fig.42
WITH THE 3 SPRINGS (SEE FIG. 42).

THE ENGINE IS READY TO BE STARTED

21 MAN-055A
4- GASOLINE and OIL

Use leaded or unleaded Premium Gasoline (92 RON+MON) mixed with oil at 6% -
(16:1). 2
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 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:

ƒ SHELL ADVANCE RACING M
ƒ ELF HTX 909
ƒ ERG K KART 2T CORSE
ƒ ERG K KART FORMULA

Once the fuel tank is filled, make sure that gasoline reaches the carburettor 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.

22 MAN-055A
 5- CARBURETTOR ADJUSTMENT GUIDE

( I ) THROTTLE ( H ) HIGH SPEED FUEL MIXTURE SCREW

SPEED SCREW

( L) LOW SPEED FUEL MIXTURE SCREW

*
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:
ƒ L (close the screw completely and then open): 1 ½ T.O.
ƒ H (close the screw completely and then open): 1 ¼ T.O.

Based on various factors as altitude, ambient temperature etc. it might be necessary to reset the carburettor 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) (L) (I)

Adjust T.O. from closed to Adjust T.O. from closed to approximately. Close by further 1 ½ T.O.
approximately: a 1 ¼ T.O after contact with throttle
1 ¼ .T.O. lever.

Start the engine and warm it. If RPM too

high adjust L counterclockwise until clutch
is disengaged.

Turn c.c.w. until max. RPM Continue to turn clockwise

is reached. Adjust further
(L) until max. R.P.M. is reached.
If RPM If RPM
fractionally for rich idle. decreases Adjust c.c.w. fractionally for
increases
Trigger accelerator Slowly adjust clockwise rich idle. Trigger accelerator.

Engine is now idling at max. attainable

RPM or slightly lower on riche side.

Adjust L counterclockwise until 2000 ÷ 2500

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.

Bad Good
adjust L slightly richer by Return to idle and check acceleration for
acceleration quick response and smooth pick-up. Acceleration Engine is ready to operate.
1/8 ÷ ¼ T.O.

23 MAN-055A
6- 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

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.

ATTENTION:
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 necessary to replace the complete assembly.
The starting procedure, from STOP position, is as follows:
A) Turn the key to KEY position (this connects 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
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 restart it in case the engine is
stopped (RUN position).
Note:
- in case the engine is stopped with the key in RUN position, to restart it, turn the
key to 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 to the
carb.) interrupt and try again after 15 seconds. Short and frequent 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).

24 MAN-055A
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 ¾ 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- RPM LIMITATION

The electronic box incorporates an RPM limiter which prevents the engine from
exceeding 17.000 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 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 of 16500 RPM
so that the incorporated limiter is not switched on continuously when the engine
is running.

9- 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 carburettor 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.

25 MAN-055A
10- 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:

ƒ L = 405÷410 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 60mm (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 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.

26 MAN-055A
11- 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.

ATTENTION:
Once the engine is started, avoid useless accelerations which can overheat and
deteriorate the clutch. Oil the chain before each test, 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:

ƒ Every 5 hours of use.
ƒ When metallic noises are heard inside the clutch.
ƒ If the kart dragging speed exceeds 6.000 RPM.
ƒ 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.

When replace the clutch?

ƒ 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.
ƒ 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 material 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.

27 MAN-055A
12- 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.

1 Seeger ring 5 Clutch drum 9 Clutch body

2 Washer 6 Screw 10 Starter ring
3 Roller cage 7 Internal washer 11 Screw
4 Sprocket 8 Locking nut

OPERATIONS TOOLS
Clutch disassembly

1. Remove the clutch cover (3 screws M6). ƒ Allen wrench 5mm-T type

2. Remove seeger ring ƒ Pliers

3. Remove external washer, clutch drum with roller

cage, inner washer
4. Apply the starter ring locking tool and remove the ƒ Locking tool: P.N. S884
M20x1 nut securing the clutch body and starter ring. ƒ 30 mm socket

ATTENTION: turn clockwise as nut has left

thread

5. Apply clutch puller tool, remove body clutch and ƒ Clutch puller tool: P.N. 10272-C
gear from crankshaft. ƒ 12 point wrench 12mm

6. Remove starter ring (3 screws M6) ƒ 12 point wrench 10 mm

28 MAN-055A
Before assembling the clutch, wash with diluent the shaft taper, the starter ring and clutch drum.

Clutch assembly

1. Install the starter ring on the clutch body by matching ƒ 12 point wrench 10 mm
the 3 holes and the dragging pin (3 screws M6) (torque at 10 Nm) (90 in-lb)
(apply “Loctite” on the threads)
ATTENTION: make sure to always install the Ø 7
mm dragging pin as, otherwise the eventual kick
backs could break the screws.
2. Install body clutch and starter ring. Apply “Loctite 641” for coaxial lockings.
3. Install clutch body fixing nut and starter gear by ƒ Locking tool: P.N. S884
means of the starter ring locking tool ƒ Allen wrench 30 mm.
(torque at 100 ÷ 110 Nm ) (885 ÷ 975 in-lb)
ATTENTION: turn counterclockwise as nut has
left thread.
4. Install the internal washer .
ATTENTION: install washer with bevel towards
internal part of the engine.
Clean the roller cage and grease it before installing it
on the crankshaft.
5. Install the clutch drum and external washer

6. Install Seeger ring ƒ Pliers

ƒ 5 mm- Allen wrench – T- Type
7. Re-assemble the clutch cover (3 screws M 6)
(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 lenghten the battery life it is necessary though to follow a few

recommendations:

ƒ When the tension drops below 12.6V it is necessary to recharge the battery.
ƒ Max. allowed recharging current is 1.8A.
ƒ 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:

ƒ Feed Tension: 90/250 Vac – 50/60 Hz
ƒ Outlet Tension: 15 V full charge – 13.8 stand-by
ƒ Max outlet current: 2A full charge
ƒ During transportation or storage, the battery could loose its charge due to self
discharge (0.1% max per day).
Fully recharge battery before use.

29 MAN-055A
 ATTENTION:
Always connect the - (negative) terminal before and the + (positive) terminal
after. Always disconnect the battery in opposite order.

ƒ Recharge the battery at least once every 6 months.

ƒ 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.
ƒ 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.
ƒ Never press or bend or overheat (by welding) the battery terminals.

Other recommendations

ƒ Pay attention not to have free fires upon or around the battery.
ƒ Never short-circuit the terminals.
ƒ Never open the battery or throw it in the fire.
ƒ In case the electrolite (diluted Sulfuric acid) gets in contact with skin or clothes,
immediately wash with water. In case it gets in touch with eyes, wash and apply for
medical assistance.
ƒ Carefully check the external case of battery and replace in case of breakages,
swellings of the case or of battery cover.
ƒ Before use, clean the battery from dust and check that the terminals are not oxidyzed
or damaged.
ƒ When the battery comes to an end never throw it in the garbage but deliver it to an
authorized disposer.

14- 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.

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) 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
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 fix correctly 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.

30 MAN-055A
 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 with 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.

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 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 of 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 excessively warm spark plug shows the ƒ Extremely clear color, porous look and
symptoms listed aside calcification of the electrodes and of the internal
insulation.
ATTENTION: ƒ Irregularities in the ignition, preignition and
Always use a warmer than standard spark plug detonation with tendency to perforate the top of
with cold or rainy climates. the piston.
ƒ Note: Some of these symptoms can be
achieved with lean mixtures.

A correct thermal degree shows ƒ Colour of the insulator end from yellow grey to
dark brown for mixtures respectively lean or rich.

An excessively cold spark plug shows the ƒ Insulator end and electrodes covered with black
symptoms, listed aside. shady soot.
ƒ Ignition difficulties.
ATTENTION: ƒ Note: a wet or oily electrode could also mean
Always use a colder than standard sparkplug an excessively rich mixture.
with hot climates.
31 MAN-055A
 COMPARISON TABLE BASED ON
THE THERMAL DEGREE
HOT

BOSCH NGK CHAMPION

WO8CS BR9EG N54R
WO7CS BR10EG N52R
WO6CS BR11EG

COLD

16- 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 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 MY'09 engine is 17.000 RPM and the RPM limiter
is calibrated at this value.

ATTENTION:
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 10 or 11 teeth sprocket (pitch: 7.775mm).

Table 1 shows the various ratios between the sprocket on the axle and the engine
sprocket given the different axle sprockets.

Tab.1

Sprocket Sprocket
Teeth n° - Engine sprocket Teeth n° - Engine sprocket
ratio ratio

Teeth n° axle 10 11 Teeth n° axle 10 11

sprocket sprocket

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 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
32 MAN-055A
 For the operaton limit of 16.500 RPM the following table N°2 has been prepared

SUGGESTION:
ƒ During the track tests we recommend use of a tachometer recording the max
obtained engine RPM.
ƒ Use sparkplug caps with a resistance of 5KΩ 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.

ƒ From table 1 with Z=10 as engine sprocket and Z=72 on the axle sprocket, a ratio of
7.20 is found.

ƒ Make a few laps on the track and, let us assume that you read 14.000 max engine
RPM.

ƒ From the table 2 to achieve a max RPM of 16.500 RPM (operating limit for the
Leopard MY'09 engine) a sprocket ratio from 8.37 and 8.60 should be used (having
used,during the tests,a sprocket ratio of 7.2 and having achieved 14.000 RPM max.).

ƒ From table.1, with these values, a sprocket ratio of 10:84 / 10:86 should be used or,
having a Z=11 on the engine sprocket, a ratio 11:92 should be used.

SPROCKET RATIO TO ACHIEVE MAX. 16500 RPM

Engine Max
RPM during
Sprocket Ratio
tests

17- REPLACEMENT OF THE STARTER BRUSHES

33 MAN-055A
 OPERATIONS PICTURES

1. DISASSEMBLE THE STARTER

- UNLOOSE THE SCREW M6 X30 ON THE

STARTER SUPPORT (See Fig.1).

(5mm ALLEN WRENCH T TYPE )

Fig.1

- REMOVE THE ADDITIONAL STARTER Fig.2

SUPPORT
3 SCREWS M6X25 (See Fig.2).

(5mm ALLEN WRENCH T TYPE)

- REMOVE THE STARTER SUPPORT

Fig.3
4 SCREWS M6x35
(See Fig.3).

(5mm ALLEN WRENCH T TYPE)

- TO REMOVE THE STARTER, UNLOOSE

3 SCREWS M6x35 (See Fig.4).

(5mm ALLEN WRENCH T TYPE)

Fig.4

- EXTRACT STARTER Fig.5

(See Fig.5).

34 MAN-055A
2. OPENING THE STARTER Fig.6
Fig.1
- UNSCREW THE SCREW M4 FIXING THE
INPUT CABLE TO THE STARTER

(see Fig.6)

(SCREWDRIVER)

Fig.7
- UNSCREW THE 3 SCREWS M5 “C” (See Fig.7)

(SCREWDRIVER)

35 MAN-055A
 - REMOVE DRUM FROM STARTER KEEPING
ROTOR IN ITS SEAT (BE SURE TO HOLD
Fig.4
THE ROTOR ON ITS TOOTHED SIDE TO
PREVENT THE BRUSHES FROM FALLING
OUT FROM THEIR SEAT) (see Fig . 8)

Fig.8

- EXTRACT ROTOR FROM THE STARTER

HEAD (see Fig. 9)
Fig.9

ATTENTION:
WHEN EXTRACTING THE ROTOR, THE
BRUSHES MAY SPRING OUT FROM THEIR
SEATS.

3. REPLACING THE BRUSH “A” Fig.10

-UNSCREW THE 2 SCREWS M4 "D"

RETAINING THE PLATE “E” (see Fig.10).

(SCREWDRIVER)

-REMOVE THE LITTLE RUBBER CAP “F” Fig.11

(see Fig.11).

(PLIERS)

OUR SUGGESTION:
SLIGHTLY OIL THE TIN PLATE TERMINAL
END, TO MAKE EASIER THE EXTRACTION
OF THE LITTLE RUBBER CAP.

36 MAN-055A
-REMOVE SILICONE FROM BRUSHES WITH A
SCREWDRIVER (see Fig. 11)

-REMOVE SPRINGS

Fig.12
- MAKING PRESSURE EXTERNALLY ON THE
TIN PLATE TERMINAL, REMOVE BRUSH. Fig.9
(See Fig. 13)

Fig.13
- INSTALL NEW BRUSH TERMINAL
(See Fig.14).

- PLACE THE LITTLE RUBBER CAP ON THE

TERMINAL.

Fig.14
- REINSTALL THE PLATE AND FIX IT
WITH HE 2 SCREWS M4
(See Fig.15).

(SCREWDRIVER)

Fig.15

37 MAN-055A
4. REPLACEMENT OF THE BRUSH “B” Fig.16

- UNLOOSE RHE SCREW M3 “G” (See Fig.16)

- EXTRACT THE BRUSH

- FIX THE NEW BRUSH WITH SCREW M6

(SCREWDRIVER)

CLOSING THE STARTER

5.
- 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" (See Fig.17).

Fig.17

- INSTALL THE 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.18).

Fig.18

OUR SUGGESTION:
TO IMPROVE THE BRUSHES LIFE, SECURE
THE LITTLE WIRES WITH SILICONE
(See Fig.19).

Fig.19

38 MAN-055A
 - CHECK THAT O-RING "H" 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. 20).

Fig.20

- TORQUETHE 3 SCREWS M5 (see Fig.21).

(SCREWDRIVER)

- CHECK THAT THE STARTER ROTOR

ROTATES FREELY.

Fig.21

- CONNECT THE INPUT WIRING

TO THE STARTER WITH THE SCREW M4 Fig.22
(see Fig.22).

(SCREWDRIVER)

6. ASSEMBLING THE STARTER

- PLACE THE STARTER IN SEAT (see Fig.23).

OIL O-RING TO MAKE EASIER
INSTALLATION N°3 SCREWS TCH M6x35
TORQUE AT A 8÷10 Nm ( 70÷90 in-lb )

- INSTALL THE STARTER ON CRANKCASE

(N°4 SCREWS M6x35).

- INSTALL THE ADDITIONAL SUPPORT

(N°3 SCREWS M6X25) AND TORQUE THE
SCREW M6X30 ON THE SUPPORT
(see Fig.23).

(5mm ALLEN WRENCH T- TYPE) Fig.23

TORQUE ALL THE SCREWS AT A 8÷10 Nm
(70 ÷ 90 in-lb)

39 MAN-055A
 18- SCHEDULED MAINTENANCE

Following some simple maintenance standards will allow the engine to perform more
reliability and have a longer life.

SCHEDULE COMPONENTS ACTIONS AND COMMENTS

Before using Exhaust flexible Check status

Exhaust spring Check status
Exhaust strap Check status
Muffler Check status and fixing
Engine sprocket Check wear
Check alignment with axle sprocket
Engine chain Check status tensioning and oil chain
Battery Check status and charge
Cables & connectors Check status and connections
Grounding of engine Check status and connections
and electronic box
Engine mount and Check torques
clamps
After use Battery Disconnect
Chain Check status and oil chain
Engine External cleaning
Every 5 ÷ 10 hours Bendix assembly Remove cover (see fig.) and clean internally

Exhaust muffler Remove muffler end, clean

Inlet silencer Open, clean
Engine head Open, clean
Clutch Open, check status of parts
Every 20 hours Piston and con-rod Check and replace worn parts
assembly
Crankshaft Check and replace worn parts
Ball bearings Check and replace worn parts

40 MAN-055A
19- TROUBLESHOOTING
Below are some common faults, their probable causes and suggested remedy:

FAULTS PROBABLE CAUSES REMEDY

Starter will not crank when Bad connections on starter cables Check and tighten
turning the key to RUN position
Bad grounding Check connections and tighten
Interruption on fuse Replace (5A) strip fuse, after
checking for eventual reversal of
battery polarity.
Damaged cables Replace
Battery connections loose Check and tighten

Battery discharged Recharge battery or replace

Starter failure Overhaul starter
Electronic box or relay failure Apply to Authorized Service Center
Starter cranks but engine won't Bad connections on cables Check connectors.
start when turning the key in
RUN position
Bad H.T. coil connection or coil Check/Replace
failure
Bad H.T. coil grounding Check grounding
Electronic box or ignition failure Apply to Authorized Service Center
Wet spark plug Replace
Malfunction on induction system Check status and connection on
fuel pipe
Replace gaskets and membranes
on carburettor
Check reed petals. Replace if
necessary
Engine starts but it stops after a Bad cable connections Check stator connector
few seconds when turning the
key in RUN position
Electronic box or ignition failure Apply to Authorized Service Center
Bad carburettor adjustment Check carburettor adjustment (see
(L screw) sect. 5)
The starter cranks also after the Electronic box failure Apply to Authorized Service Center
engine is running.
Rough idle Bad carb idle adjustment Check carburettor adjustment (see
( screw I) sect. 5)
Drop in engine performance Bad compression Check piston
Bad carburettor adjustment Check carburettor adjustment (see
sect.5)
Insufficient gas flow Check fuel flow lines and inlet filter
Dirty inlet silencer Check and clean
Burning smell, smoke Overheating of clutch Check clutch (see Sect. 11)
Clutch engages at too high RPM Excessive wear of friction material Check clutch (see Sect. 11)
Exhaust too noisy Flexible damaged Check and replace if necessary
Springs damaged or lost
Insulating strap damaged
Damaged exhaust header

41 MAN-055A
20- ENGINE PRESERVATION

When engine is to remain unoperative for a long period it must be preserved as

follows:

ƒ Disconnect the battery and charge it periodically (see Sect. 12)

ƒ Disconnect carburettor and clean it
ƒ 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

42 MAN-055A
43 MAN-055A