IAME MINI SWIFT 60CC - USA User manual

MAN-85 –USA
Installation MANUAL
“MINI SWIFT 60CC - USA”

1
MAN-85 –USA
INDEX
GENERAL DESCRIPTION OF THE ENGINE
CHARACTERISTICS OF THE ENGINE – OPERATIONAL LIMITS
1- Contents of packing
2- Motor Identification Number
3- Preparation and installation of the engine on the chassis
3.1 Installation sketch of the engine on the chassis
3.2 Exhaust header assembly
3.3 Preparation and installation of the motor-mount
3.4 Install the carburetor
3.5 Install the engine on the chassis
3.6 Install the clutch cover with H.T. coil
3.7 Installation Electrical connections
3.8 Electrical connections on the engine
3.9 Install the intake silencer
3.10 Install the exhaust
4- Gasoline and Oil
5- Tillotson HW-31A carburettor adjustment
6- Starting and stopping the engine
7- Engine break-in
8- Inlet silencer
9- Recommendations on the exhaust system
10- Centrifugal clutch
11- Instructions for the disassembly /assembly of the clutch
12- Battery
13- Use of the battery charger
14- Spark-plug and thermal degree
15- Choice of the best sprocket ratio
16- Scheduled maintenance
17- Troubleshooting
18- Engine preservation
attachments: - Fastener Torque Table
- Wiring Diagram
PAGE
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MAN-85 –USA
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, either for hobby or 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 and lasting of components, when the operating limits 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 possibile stability and sliding homogeneity.
The head is separated from the cylinder and secured by studs.
The crankshaft is built and supported by ball-bearings. The crankshaft is of steel alloy,
hardened and tempered, as is the connecting rod which runs on roller bearings.
The ignition includes a 2 pole stator/rotor, an H.T. coil, a starter relay and complete wiring
harness.
The spark is generated also without a battery: it is therefore possibile, in case of
emergency, to start the engine with an external starter unit.
The engine has an integrated electric starter. By pushing the green start button, the starter
activates a Bendix type gear which engages the starter ring assembled on the clutch.
The engine is provided with a dry centrifugal clutch with low maintenance and with
interchangeable sprocket .
The carburettor type is a diaphragm (series Tillotson HW) includes an integrated fuel pump
and filter, and is able to operate in any position.
The battery (12 V- 7.2Ah) is a sealed, no maintenance, battery is NOT supplied, the
battery supports box be easily adapted to all existing chassis.
The exhaust, included in the supply, is already tuned for the best possibile performance.
The engine is also equipped with a centrifugal dry clutch with low maintenance with
incorporated sprocket.
The exhaust system, including in the supply, is already tuned and optimized to ensure the
best possible performance.

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MAN-85 –USA
ENGINE CHARACTERISTICS – OPERATIONAL LIMITS
The characteristics of the engine are the following :
 Cycle: OTTO / 2 stroke
 Original cubic capacity: 59.00 cc
 Original bore 41.80
 Max. theoretical bore: 42.10 mm
 Stroke : 43.00 mm
 Lubrication : fuel-oil mix 6%
 Induction: inlet in 3rd port (Piston Port)
 Carburetor: Diaphragm type, Tillotson HW-31A (Ø17mm)
 Cooling : Free air
 Ignition : Analogic / 2 poles, with internal rotor
 Electric starter: 12V / 0.15 Kw
 Clutch : Automatic, dry centrifugal
Operational limits:
 Max.RPM / 1’ : 14.500 RPM
ATTENTION:
Never exceed the above limits, no obligation of IAME exists in case the above
limits are exceeded.
1- CONTENTS OF PACKING
Each engine is supplied with the accessories under shown:
EXHAUST
Quantity
 Exhaust silencer spring
2
 Exhaust manifold
1
 Exhaust muffler
1
INDUCTION
 Tillotson carburettor
1
 Intake silencer
1
 Intake silencer support
1
ELECTRIC PLANT
 Battery support
1
 Battery fixing strap
1
 Battery fixing clamps
2
 Electrical harness
1
 Push buttons support bracket
1
 Starter relay
1
 NGK BR 9 EG spark plug
1
 Spark plug cap
1
 Fixing clamps
8
MISCELLANEOUS
 Clutch cover with coil
1

2
MAN-85 –USA
ACCESSORIES
COPERCHIO FRIZIONE
SILENZIATORE DI ASPIRAZIONE
EXHAUST GROUP
ELECTRIC WIRES
BATTERY SUPPORTS
CLUTCH COVER
INTAKE SILENCER
NGK SPARK PLUG
TILLOTSON HW-31A CARBURETTOR
INTAKE GROUP

3
MAN-85 –USA
2- MOTOR IDENTIFICATION NUMBER
The official identification number can be found stamped on the lower left part of the
crankcase, next to the electric starter (see fig.). The number normally includes a letter
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 engine.
NOTE:
In case of need for spare parts and when contacting the IAME Support Centers,
please always refer to the Motor Identification Number and to the motor model.

4
MAN-85 –USA
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

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MAN-85 –USA
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 GASKET IS PROVIDED
TO PROTECT THE INTERNAL PARTS.
3.2.1 REMOVE NUTS AND EXHAUST COVER.
3.2.2 INSTALL SPRINGS ON THE EXHAUST
HEADER (SEE FIG 1).
MAKE SURE THAT THE EXHAUST GASKET IS
IN SEAT AND INSTALL THE EXHAUST
HEADER (SEE FIG 2).
NOTE:
ON THE “BABY” VERSION THE EXHAUST
HEADER IS NOT REQUIRED.
3.2.3 INSTALL THE 2 WASHERS 6mm
SUGGESTION:
PUT THE ENGINE IN HORIZONTAL POSITION
(USE A SCREWDRIVER IF NECESSARY) AND
INSTALL THE WASHERS IN SEAT.
3.2.4 INSTALL THE 2 NUTS
(SEE FIG 3).
TORQUE AT 9 ÷ 11 Nm (80 ÷ 100 in-lb)
“T” WRENCH 10 mm
Fig.3
Fig.1
Fig.2

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MAN-85 –USA
3.3
PREPARATION AND INSTALLATION OF THE MOTOR-MOUNT
NOTE: ALL THE DIMENSIONS ARE IN MILLIMETERS
3.3.1 DRILL 4 HOLES (DIAM. 8.5mm) INTO THE MOTOR-MOUNT .
3.3.2 INSTALL THE MOTOR-MOUNT. MAKE
SURE TO USE M8 ALLEN SCREWS WITH A
LENGTH 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. 4 AND DRAW. )
4 ALLEN SCREWS M8
TORQUE AT 22÷24 Nm (190 ÷ 210 in-lb)
(6mm ALLEN WRENCH)
3.4
INSTALL THE CARBURETTOR
 REMOVE THE PLASTIC CAP
 KEEPING 1 CARBURETTOR GASKET ON
THE ENGINE, INSTALL:
(SEE FIG.10)
- N.2 THERMICAL SPACER
(15mm+11.5mm)
- N.2 CARBURETTOR GASKET
- CARBURETTOR
- N.2 COLOMN NUTS
12 POINT WRENCH 5mm
-CONNECT BY APPROPRIATE PIPE; THE
INTAKE PRESSURE MANIFOLD ON THE
CARBURETTOR AND THE INTAKE PRESSURE
MANIFOLD ON THE CRANKCASE.
MOTOR-MOUNT HORIZONTAL VIEW
Fig.4
Fig.10

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MAN-85 –USA
3.5
INSTINSTALL THE ENGINE ON
CHASSIS
3.5.1 PLACE THE ENGINE ON THE 2 OUTSIDE
MAIN RAILS AND FIX THE MOTOR-MOUNT
WITH THE TWO CLAMPS (SEE FIG.12).
SUGGESTION:
NEVER TORQUE COMPLETELY THE CLAMPS
UNTIL THE CHAIN IS INSTALLED AND
PROPERLY ALIGNED.
3.5.2 CHECK THE ALIGNMENT OF THE
ENGINE SPROCKET AND THE AXLE
SPROCKET (SEE FIG. 13).
3.5.3 INSTALL THE CHAIN (PITCH: 7.775).
(SEE FIG. 14).
3.5.4 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. 15)
3.5.5 TORQUE THE CLAMPS SCREWS
Fig.12
Fig.13
Fig.14
Fig.15
15mm

8
MAN-85 –USA
3.6
INSTALL THE CLUTCH COVER WITH
H.T. COIL
3.6.1 REMOVE THE 3 SCREWS M6x30 ON THE
CRANKCASE (SEE FIG. 16-A) AND INSTALL
THE CLUTCH COVER WITH H.T. COIL
(SEE FIG.16-B)
TORQUE THE 3 SCREWS AT 8 ÷ 10 Nm
(70 ÷ 90 In-lb)
(5 mm ALLEN WRENCH)
ATTENTION:
MAKE SURE THAT THE COPPER 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.
Fig.16-A
Fig.16-B

9
MAN-85 –USA
ELECTRICAL CONNECTIONS
(refer to the attached electrical schematic)
3.7
INSTALL THE CLAMPS ON THE BATTERY
SUPPORT (SEE FIG.17).
N°2 SCREWS M6x10
TORQUE SCREWS AT 8÷10 Nm
(70 ÷ 90 in-lb)
(12 POINT WRENCH 10 mm)
3.7.1 POSITION THE SUPPORT ON THE
CHASSIS REAR RAIL
(SEE FIG.18).
3.7.2 FIX THE CLAMPS (SEE FIG.19).
N° 2 SCREWS M6x25
TORQUE SCREWS AT 8÷10 Nm
(70 ÷ 90 in-lb)
(5 mm ALLEN WRENCH )
3.7.3 INSERT THE STRAP INTO THE
SUPPORT SLOTS
(SEE FIG.20).
Fig.18
Fig.19
Fig.20
Fig.17

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MAN-85 –USA
3.7.4 POSITION THE BATTERY ON THE
SUPPORT (SEE FIG.21).
SUGGESTION:
NEVER CONNECT THE BATTERY UNTIL
YOU ARE READY TO START THE ENGINE.
ATTENTION:
PAY ATTENTION NOT TO SHORT CIRCUIT
THE BATTERY TERMINALS AS BATTERY
COULD BE DAMAGED BEYOND REPAIR.
3.7.5 CONNECT THE STARTER RELAY TO
THE CABLE TERMINALS (SEE FIG.22).
NOTE:
THE 2 CABLES PROVIDED WITH 10mm
TERMINALS CAN BE INVERTED ON THE
STARTER RELAY, WITHOUT CAUSING ANY
MALFUNCTION PROBLEMS.
ALSO THE 2 CABLES WITH 6.3mm
TERMINALS CAN BE INVERTED .
3.8
ELECTRICAL CONNECTIONS ON
THE ENGINE (REFER TO THE
ATTACHED ELECTRICAL SCHEMATIC)
UNSCREW THE M6 SCREW ON THE
STARTER AND CONNECT THE GROUND
CABLE TO THE ENGINE.
(SEE FIG.23).
TORQUE SCREW AT 8÷10 Nm
(70 ÷ 90 in-lb)
(5 mm ALLEN WRENCH)
3.8.1 CONNECT THE TERMINAL (8mm) OF
THE HARNESS TO THE STARTER (SEE
FIG.24).
Fig.21
Fig.22
Fig.21
Fig.23
Fig.24

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MAN-85 –USA
3.8.2 CONNECT THE TERMINAL OF THE
IGNITION STATOR TO THE H.T. COIL (SEE
FIG.25).
3.8.3 CONNECT THE SECOND TERMINAL
OF THE IGNITION STATOR TO THE "MALE"
CONNECTOR OF THE HARNESS (SEE
FIG.26).
3.8.4 FIX THE HARNESS WITH PLASTIC
CLAMPS, ALONG THE CHASSIS REAR RAIL
(SEE FIG.27).
3.8.5 FIX THE BATTERY AND HARNESS
TERMINALS BY MEANS OF THE STRAP
(SEE FIG.28).
Fig.25
Fig.26
Fig.27
Fig.28

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MAN-85 –USA
3.8.6 FIX THE STARTER RELAY TO THE
FIXING STRAP BY MEANS OF A CLAMP, OR
FIX IT TO THE BATTERY SUPPORT WITH
THE BIADHESIVE TAPE (SEE FIG.29).
ATTENTION :
NEVER LET THE HARNESS GET IN TOUCH
WITH THE GROUND OR WITH ROTATING
PARTS AS IT COULD BE DAMAGED
BEYOND REPAIR.
3.8.7 FIX THE REMAINING HARNESS
ALONG THE RAIL, BRAKE SIDE, WITH
PLASTIC CLAMPS.
(SEE FIG.30).
3.8.8 REMOVE THE STEERING WHEEL AND
POSITION THE PUSH BUTTON SUPPORT
BRACKET ON THE HUB. (SEE FIG.31).
3.8.9 ASSEMBLE THE PUSH BUTTONS INTO
THE SUPPORT BRACKET (SEE FIG.32).
Fig.29
Fig.27
Fig.30
Fig.31
Fig.32

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MAN-85 –USA
3.8.10 CONNECT THE BUTTON
CONNECTORS WITH THE HARNESS
CONNECTORS (SEE FIG.33).
ATTENTION :
PAY ATTENTION TO MATCH THE
CONNECTORS ACCORDING TO THE
CORRESPONDING COLOUR IN ORDER TO
CONNECT THEM PROPERLY.
3.8.11 TIGHTEN THE SPARK PLUG CAP ON
THE H.T. COIL CABLE
(SEE FIG. 34).
3.8.12 FIX THE SPARK-PLUG CAP ON THE
H.T. CABLE WITH A PLASTIC CLAMP (SEE
FIG. 35).
- INSTALL THE SPARK PLUG SUPPLIED
WITH THE ENGINE
TORQUE AT 20 ÷ 26 Nm (175 ÷ 230 in-lb)
- POSITION THE SPARK PLUG CAP ON THE
SPARK-PLUG.
Fig.33
Fig.34
Fig.35
Caution should be taken when installing the spark plug. Always clean and inspect the
spark plug threads before installation. Always apply anti seize compound, grease or oil.
- NEVER INSTALL THE SPARK PLUG WITHOUT SOME LUBRICATION -
You should be able to freely turn the plug into the head using only your fingers to turn
the plug. Do not force the plug with a tool or damage will occur. After rotating the plug
into the head by hand only. Torque to 175-230 lbs-in (20÷26 Nm).

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MAN-85 –USA
3.8.13 MAKE SURE THAT THE BATTERY IS
PROPERLY CONNECTED BEFORE
STARTING THE ENGINE. (SEE FIG. 36).
3.9
INSTALL THE INTAKE SILENCER
- MAKE SURE THAT THE AIR FILTER
HAS THE INLET HOLE TOWARDS
UPPER SIDE AND THAT IT IS NOT
PLUGGED.
- TIGHTEN THE FIXING CLAMP ON THE
CARB. AND FIX THE FILTER BY MEANS
OF THE PROPER CLAMP ON THE
CHASSIS RAIL
(SEE FIG. 37-38).
3.10
INSTALL THE EXHAUST SYSTEM
INSTALL THE EXHAUST MUFFLER ON THE
FITTING AND SECURE IT WITH THE 2
SPRINGS. (SEE FIG. 39).
NOTE:
ON THE “BABY” VERSION, THE MUFFLER
IS DIRECTLY POSITIONED ON THE
CYLINDER WITHOUT ANY INTERMEDIATE
FITTING
ENGINE IS READY TO BE STARTED
Fig.37
Fig.36
Fig.38
Fig.39

15
MAN-85 –USA
4- GASOLINE AND OIL
Use (leaded) or unleaded gasoline, mixed with oil at 6% (16:1).
Use oil 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:
 WLADOIL K 2T KART RACING OIL
 SHELL ADVANCE RACING M
 ELF HTX 909
Once the fuel tank is filled, make sure that the 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. pump and the vent tube on the tank and
pressurize the vent tube, until gasoline comes out from the tube on the carb.
pump. Make sure that there is no air in the tube.
Connect the tube on the carb. and on the vent.

16
MAN-85 –USA
5-TILLOTSON HW-31A CARBURETTOR ADJUSTEMENT
LEAN 1 T.O.*RICHE
¾T.O. 1 ¼T.O.
*T.O. = TURNS OPEN 1 ½T.O.
Normally the correct setting of the mixture screws, after engine run-in, is the following:
 L (close the screw completely and then open): 1 T.O. + ¼ (1 turn and 15’)
 H (close the screw completely and then open): ¾ T.O. (45’)
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 )HIGH SPEED FUEL
MIXTURE REGIM
I
( L ) LOW SPEED FUEL
MIXTUREREGIMI
( I ) TROTTLE
SPEED SCREW

17
MAN-85 –USA
6- STARTING AND STOPPING THE ENGINE
Press the green button on the steering wheel to start the engine.
If the engine cannot be started, stop and try again (check that gas gets into the carb.).
Short and frequent tries are better than long ones.
In case the engine can't be started, refer to the Sect. 17 ” Troubleshooting".
The engine can be stopped by pressing the red button on the steering wheel. Keep the
button pressed until the engine has got to a complete stop.
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, closing and opening gently the carb. throttle (if a tachometer is
installed never exceed 8.000 RPMs). 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 approx. 5 minutes at max. speed, with throttle wide open
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- INLET SILENCER
Make sure that the inlet hole on the filter is towards the upper side and that it is not
plugged. Make sure that the clamp on the carburetor is not loosen and that the filter is
well fastened to the chassis rail.
Once a while, clean the inside from oil deposits. If necessary remove the rubber filter
fitting and clean it with gasoline or solvent.
9- RECOMMENDATIONS ON THE EXHAUST SYSTEM
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 2 springs in place, as
otherwise the exhaust pipe could vibrate beyond control.
Every 1015 hours, open the exhaust pipe end and make sure that the holes on the
internal counter cone are not plugged.