IAME EASY-KART 2003 Installation instructions

MAN-028
EASY-KART ENGINES
2003
ASSEMBLY INSTRUCTIONS
and
USER MANUAL

MAN-028
1
INDEX
GENERAL DESCRIPTION OF THE ENGINE
CHARACTERISTICS OF THE TaG ENGINES – OPERATIONAL LIMITS
1- Contents of the packing
2- Motor identification Number
3- Preparation and installation of the engine on the chassis
3.1 Exhaust header assembly
3.2 Preparation and installation of the motor-mount
3.3 Install the carburetor
3.4 Install the engine on the chassis
3.5 Install the clutch cover with H.T. coil
3.6 Installation and connection of the power pack box
3.7 Electrical connections on the engine
3.8 Installation of the intake silencer
3.9 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- Scheduled maintenance
15- Troubleshooting
16- Engine and accessories preservation
Attachments: - Fastener Torque Table
- Wiring diagram
Page
1
3
4
5
6
6
7
8
10
12
13
14
17
18
19
20
22
22
23
23
24
25
27
28
29
30
31
32
33

1
GENERAL DESCRIPTION OF THE ENGINE
The “TaG” engines have 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 considered, in order to guarantee the highest reliability of components,
under the condition that the operating limitations are respected.
Depending on the final destination and use of the vehicle (age and weight of drivers, if for
real or hobby racing etc) different versions of the engines are available, based on different
cubic capacities, different engine powers, type of induction (either piston port or reed
valve) and type of cooling (air or water).
In particular the EASY-KART line of engines include:
•Engine 62cc - Air cooled engine
- Piston Port Type
•Engine 100cc/125cc - Air cooled engines
- Reed valve
The motors are with single cylinder using the two stroke principle.
The cylinder and the crankcase are in light alloy.
The pressed in liner is made of centrifugated cast iron, machined from the full to guarantee
the best possible stability.
The head is separated from the cylinder and secured by studs.
The crankshaft is built up 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 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 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.
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2
MAN-028
The carburetor is a diaphragm Tillotson carburetor with fixed jet on the High speed,
integral fuel pump and filter and has an all position mounting.
The battery (12 V- 7.2Ah) is a sealed type, without maintenance battery and is supplied
already preassembled in the battery and 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.

3
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CHARACTERISTICS OF THE TaG ENGINES - OPERATIONAL LIMITS
1. The characteristics which are in common to all TaG engines are the following.
Between brackets, the exceptions and possible alternatives are shown :
•Cycle: OTTO / 2 stroke
•Lubrication : Fuel-Oil mix
•Induction: Piston port on 62cc engine.
Reed valve on 100/125cc engines.
•Carburetor: Membrane , Tillotson with fixed jet on the H.
•Cooling : Air, standard on all engines
•Ignition: Digital / 4 poles with internal rotor
•Battery charge: With integral generator
•Electric start: 12V/0.30 Kw (12V/0.15 Kw on the 62cc only )
•Clutch: Automatic, dry, centrifugal
2. OPERATIONAL LIMITS:
•Max RPM : 12500 RPM on 62cc.
15500 RPM on 100/125cc.
ATTENTION:
Never exceed the above limits. No obligation of IAME exists in case the above
limits are exceeded.
3. CHARACTERISTICS VALID FOR EACH MODEL
MOTORE
62 cc. 100 cc. 125 cc.
Original cubic capacity (cc) 61.42 98.30 123.67
Original bore (mm) 42.50 50.80 54.00
Max. theoretical bore (mm) 42.70 51.23 54.28
stroke (mm) 43.30 48.50 54.00

4
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1- CONTENT OF THE PACKING
Each engine of the TaG series is delivered with the under shown accessories
which are preinstalled on the EASY-KART chassis.
PISTON PORT
ENGINE 62 cc.
REED VALVE
ENGINE 100/125 cc.
AIR AIR
EXHAUST
•Flexible 1 1
•Spring For Flexible 3 3
•Exhaust Fiber Strip 1 1
•Exhaut Header 1 1
•Exhaust Muffler 1 1
INDUCTION
•Tillotson Carburetor 1 1
•Intake Silencer 1 1
•Intake Silencer Support 1 1
•Pressure Fitting Tube 1 -
•Accelerator Cable Bracket 1 1
ELECTRICAL
•Battery 12 V 1 1
•Battery Support 1 1
•Battery Strap 1 1
•Battery Clamps 2 2
•Power Pack Box with Harness 1 1
•Plastic Fixing Clamps 8 8
•NGK BR 10 EG Spark Plug 1 1
•Spark Plug Cap 1 1
MISCELLANEOUS
•Additional Engine Plate - 1
•Water proof cover 1 1
•Clutch cover with H.T. coil 1 1

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2- MOTOR IDENTIFICATION NUMBER
The official motor identification number can be found stamped in the lower left part of
the crankcase, aside of the electric starter (see fig.) The number normally includes 2
letters “EK” followed by 4 digits. 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.

6
MAN-028
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.
3.1
EXHAUST HEADER ASSEMBLY
NOTE:
THE ENGINE IS SUPPLIED WITH THE
EXHAUST GASKET AND NUTS ALREADY
INSERTED. WHEN THE SHIPMENT IS MADE
AN EXHAUST STIFFENER IS INSERTED TO
PROTECT THE INTERNAL PARTS.
3.1.1 REMOVE THE TWO NUTS AND THE
EXHAUST STIFFENER..
3.1.2 MAKE SURE THE EXHAUST GASKET IS
IN SEAT AND INSTALL THE EXHAUST
HEADER (SEE FIG 1).
3.1.3 INSTALL THE TWO 8mm WASHERS
SUGGESTION:
EVENTUALLY PUT THE ENGINE IN
HORIZONTAL POSITION AND DRIVE THE
WASHERS WITH A SCREWDRIVER.
3.1.4 INSTALL THE TWO NUTS.
TORQUE AT 18 ÷ 22 Nm
SUGGESTION:
IN CASE IT IS DIFFICULT TO TORQUE THE
INTERNAL HEADER NUT (SEE FIG.2).
REDUCE THE EXTERNAL DIAMETER OF THE
WRENCH TO 18.5mm OR USE AN OPEN
WRENCH.
13 mm SOCKET WRENCH (OR 13 mm OPEN WRENCH.)
Fi
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.1
Fi
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.2

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3.2 PREPARATION AND INSTALLATION OF THE MOTOR MOUNT
3.2.1 DRILL 4 HOLES (DIAM 8.5mm) IN THE MOTOR MOUNT
IN CASE THE SUPPLY INCLUDES THE ADDITIONAL MOTOR MOUNT
MOTOR MOUNT HORIZONTAL VIEW
MOTOR MOUNT HORIZONTAL VIEW

8
MAN-028
3.2.2 BEFORE INSTALLING THE MOTOR
MOUNT, POSITION THE ADDITIONAL MOUNT
PLATE (IF INCLUDED IN THE SUPPLY) ON
THE CRANKCASE (SEE FIG. 3).
3.2.3 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 APPR. 18mm (THE SCREW MUST
PROTRUDE FROM THE PLATE FOR APPR.
18mm) (SEE FIG. 4 AND DRAW. PAG. 7)
4 ALLEN SCREWS M8 – TORQUE AT 22÷24
Nm
6 mm ALLEN WRENCH.
INSTALL THE CARBURETOR
3.3
3.3.1 INSTALL THE GAS CABLE CLAMP ON
THE SUPPORT (SEE FIG. 5)
12 POINT WRENCH 10mm
Fi
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.3
Fi
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.4
Fi
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.5

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3.3.2 REMOVE 2 SCREWS 3.5mm ON THE
CARB. PUMP (IN CORRESPONDENCE OF THE
THROTTLE LEVER) (SEE FIG. 6).
SCREWDRIVER 4.8 mm.
3.3.3 INSERT THE GAS BRACKET AND THE
TWO SCREWS (SEE FIG. 7).
3.3.4 INSTALL THE INTAKE SUPPORT – 2
SCREWS M5 X10 (SEE FIG. 8)
3 mm ALLEN WRENCH
3.3.5 INSTALL THE CARBURETOR –
REED VALVE ENGINE (SEE FIGG. 9/10).
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.
10mm OPEN WRENCH
Fi
g
.6
Fi
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.7
Fi
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.8
Fi
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.9

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MAN-028
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 WASHERS.
TORQUE AT 6 ÷ 10 Nm.
3.3.5 INSTALL THE CARBURETOR -
PISTON PORT ENGINE
•REMOVE THE 2 NUTS M6.
•REMOVE THE PLASTIC PLUG .
•LEAVE ONE CARB. GASKET ON THE
ENGINE AND INSTALL, IN THE ORDER
(SEE FIG. 11):
- N.1 PLASTIC SPACER
- N.1 CARB. GASKET
- CARBURETOR
- N.2 WASHERS
- N.2 NUTS M6
-
TORQUE AT 6 ÷ 10 Nm
•CONNECT THE PRESSURE HOSE BOTH
ON THE CRANKCASE AND ON THE
CARB. FITTINGS (SEE FIG. 12).
3.4 INSTALL THE ENGINE ON THE
CHASSIS
3.4.1 POSITION THE ENGINE ON THE 2
OUTSIDE MAIN RAILS AND FIX THE MOTOR-
MOUNT WITH THE TWO CLAMPS (SEE
FIG.13)
SUGGESTION:
NEVER TORQUE COMPLETELY THE CLAMPS
UNTIL THE CHAIN IS INSTALLED AND
PROPERLY ALIGNED.
Fi
g
.10
Fi
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.11
Fi
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.12
Fi
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.13

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MAN-028
3.4.2 CHECK THE ALIGNMENT OF THE
ENGINE SPROCKET AND THE AXLE
SPROCKET (SEE FIG. 14).
3.4.3 INSTALL THE CHAIN (PITCH: 7.775) (SEE
FIG. 15).
3.4.4 MOVE THE ENGINE ON THE RAILS AND
OPTIMIZE THE CHAIN TENSION .
ATTENTION:
THE PLAY OF THE CHAIN MUST BE APPR.
15mm MEASURED IN THE SHOWN POINT
(SEE FIG. 16)
3.4.5 TORQUE THE CLAMP SCREWS
Fi
g
.14
Fi
g
.15
Fi
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.16
15mm

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INSTALL THE CLUTCH COVER WITH
H.T. COIL
3.5
3.5.1 REMOVE THE 3 SCREWS M6 X 30 ON
THE CRANKCASE (SEE FIG. 17) AND INSTALL
THE CLUTCH COVER WITH H.T. COIL (SEE
FIG.18).
TORQUE THE 3 SCREWS AT 8 ÷ 10 Nm
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 DAMAGE THE COIL BEYOND REPAIR.
5mm ALLEN
Fi
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.17
Fi
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.18

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ELECTRICAL CONNECTION
(refer to the attached electrical schematic)
3.6 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 INSTRUCTIONS.
3.6.1 EXTRACT THE BATTERY FROM THE
SUPPORT AFTER HAVING UNLACED THE
BATTERY STRAP (SEE FIG. 19).
3.6.2 POSITION THE SUPPORT CLAMPS ON
THE OUTSIDE RAIL (BRAKE SIDE) AT THE
HEIGHT OF THE SEAT.
FIX THE CLAMPS BY HAND WITH 2
SCREWS M6 X 25 (SEE FIG. 20).
3.6.3 POSITION THE BATTERY SUPPORT
BOX ON THE CLAMPS MATCHING THE
ATTACHMENT HOLES (SEE FIG. 21).
FIX THE BOX WITH TWO SCREWS M6 X 10.
MOVE THE BOX WITH THE 2 CLAMPS TO
THE MOST SUITABLE POSITION.
TORQUE THE M6 SCREWS AT 8 ÷ 10 Nm
12 POINT WRENCH 10mm
Fi
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.19
Fi
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.20
Fi
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.21

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MAN-028
3.6.4 INSERT THE BATTERY STRAP (SEE
FIG. 22).
3.6.5 INSERT THE BATTERY WITH
TERMINALS TOWARDS THE OUTSIDE (SEE
FIG. 23).
CONNECT THE BATTERY TERMINALS.
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.
ATTENTION:
PAY ATTENTION NOT TO SHORT CIRCUIT
THE BATTERY TERMINALS AS BATTERY
COULD BE DAMAGED BEYOND REPAIR.
ELECTRICAL CONNECTIONS ON
THE ENGINE
3.7
3.7.1 GROUND THE POWER PACK.
ATTENTION:
AN INADEQUATE GROUNDING OF THE
POWER-PACK BOX COULD DAMAGE THE
BOX BEYOND REPAIR. MAKE SURE TO
CAREFULLY FOLLOW THE UNDER SHOWN
INSTRUCTIONS.
3.7.2 POSITION THE HARNESS FROM THE
POWER-PACK BOX ALONG THE CENTRAL
RAIL , UNDERNEATH THE SEAT, AND
TIGHTEN WITH PLASTIC CLAMPS (SEE FIG.
24).
ATTENTION:
NEVER LET THE HARNESS GET IN TOUCH
WITH THE GROUND OR WITH ROTATING
PARTS AS IT COULD BE DAMAGED
BEYOND REPAIR.
Fi
g
.22
Fi
g
.23
Fi
g
.24

15
MAN-028
3.7.3 FIX THE GROUND CABLE, FROM THE
POWER-PACK, ON THE ENGINE
CRANKCASE, BY MEANS OF THE PROPER
THREADED HOLE (SEE FIG. 25).
ATTENTION:
THIS OPERATION IS EXTREMELY
IMPORTANT AS AN UNCERTAIN
GROUNDING COULD DAMAGE THE POWER
PACK BOX BEYOND REPAIR.
3.7.4 CONNECT THE TERMINALS (3 AND 4
WAYS) ON THE HARNESS FROM THE
POWER PACK BOX WITH THE TERMINALS
ON THE CABLES FROM THE IGNITION (SEE
FIG. 26/27).
ATTENTION:
MAKE SURE THAT THE FIXING TONGUES
ARE PROPERLY INSERTED TO
GUARANTEE THE BEST POSSIBLE
CONNECTION OF THE TERMINALS.
3.7.5 CONNECT THE CABLE TERMINAL
(SINGLE), FROM THE POWER-PACK, WITH
THE CABLE TERMINAL ALREADY
CONNECTED TO THE STARTER (SEE
FIG.28).
ATTENTION:
MAKE SURE THAT THE FIXING TONGUE IS
PROPERLY INSERTED TO GUARANTEE
THE BEST POSSIBLE CONNECTION OF THE
TERMINALS.
Fi
g
.25 Fi
g
.25
Fi
g
.26
Fi
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.27
Fi
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.28

16
MAN-028
3.7.6 CHEK THE ELECTRIC STARTER
CABLE FIXING (SEE FIG. 29) AND
COMPLETE THE FIXING OF THE HARNESS
(SEE FIG. 30).
ATTENTION :
NEVER LET THE HARNESS GET IN TOUCH
WITH THE GROUND OR WITH A ROTATING
PART AS IT COULD BE DAMAGED BEYOND
REPAIR.
3.7.7 CONNECT THE COIL CABLE FROM
THE POWER PACK TO THE TERMINAL ON
THE COIL (SEE FIG. 31).
SUGGESTION:
SEAL THE TERMINAL ON THE COIL WITH
PLASTIC TAPE TO AVOID THAT EVENTUAL
VIBRATIONS MIGHT DISCONNECT THE
TERMINAL.
3.7.8 INSERT THE SPARK PLUG CABLE
THROUGH THE SUPPORT SPRING ON THE
CYLINDER (SEE FIG. 32).
Fi
g
.29
Fi
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.30
Fi
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.31
Fi
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.32

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3.7.9 PUNCTURE THE INSULATING
MATERIAL ON THE H.T. CABLE WITH THE
END OF THE CAP SPRING SO THAT THE
SPRING IS IN SURE CONTACT WITH THE
INTERNAL WIRE (SEE FIG. 33).
3.7.10 INSERT THE SPARK PLUG CAP ON
THE SPRING (SEE FIG. 34). 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.
3.8 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
CHASSIS SIDE RAILS WITH PLASTIC
CLAMPS (SEE FIG. 35/36)
Fi
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.33
Fi
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.34
Fi
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.35
Fi
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.36

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3.9 INSTALL THE EXHAUST
NOTE:
SEE SECTION 9 FOR RECOMMENDATIONS
ON THE IDEAL LENGHT OF THE EXHAUST.
3.9.1 INSTALL THE FLEXIBLE (L= 65mm –
FLEXIBLE COMPLETELY CLOSED) AND THE
EXHAUST HEADER (SEE FIG. 37) AND
CONNECT THE EXHAUST.
3.9.2 INSTALL THE FIBER STRIP AROUND
THE FLEXIBLE AND FIX WITH THE 3
SPRINGS (SEE FIG. 38).
THE ENGINE IS READY TO BE STARTED
Fi
g
.37
Fi
g
.38