IAME ReedJet AUS 100cc-TaG User manual

MAN-033
REEDJET AUS 100cc – TaG
01/11/04
INSTALLATION MANUAL

MAN-072
1
GENERAL DESCRIPTION OF ENGINE
This engine of the "TaG" series (Touch and Go) has been expressly designed and
developed to power 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 applied, in order to guarantee the highest reliability
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
possible 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: therefore, in case of emergency, the engine
can be started with an external starter unit.
The engine has an integrated electric starter. By pushing the start button, the starter activates
a Bendix type gear that 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 is a diaphragm type (series Tillotson HL), it includes an integrated fuel pump
and filter, and it is able to operate in any position.
The battery (12 V - 9Ah) is a sealed, no maintenance battery and is supplied together with a
support box, which can be easily adapted to all existing chassis.
The exhaust system, included in the engine package, is already tuned and optimized to
ensure the best possible performance.

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ENGINE FEATURES – OPERATIONAL LIMITS
Engine features:
Cycle:
Original cubic capacity:
Original bore:
Max. theoretical bore:
Stroke:
Lubrification :
Induction:
Carburettor:
Cooling:
Ignition:
Electric Starter:
Clutch:
OTTO / 2 stroke
100 cm³
48.20 mm
48.53 mm
54.05 mm max
Mixture 5%
Reed Valve in crankcase
Diaphragm type , Tillotson HL 398A - Ø23mm
Free Air
Analogical / 2 poles, slotted with internal rotor
12V/0.30 kW
Automatic, dry centrifugal
ATTENTION:
Never exceed the above limits, no obligation of IAME S.p.A. exists in case the above
limits are exceeded.
Operational RPM limits (the motor not included RPM Limiter):
Max.RPM / 1’ : 15.000 RPM
CONTENT OF THE ENGINE PACKAGE
EXHAUST GRUOP
Quantity
Exhaust muffler spring
2
Exhaust manifold (no restricted / restricted Ø19mm)
1
Exhaust muffler
1
INDUCTION GROUP
Tillotson Carburettor HL 398A (Venturi Ø23mm)
1
Inlet Silencer
1
Inlet Silencer Rubber Manifold
1
Inlet Silencer Support + Clamps
1
Carburettor throttle lever cable
1
Inlet manifold carburettor pipe
1
ELECTRICAL GROUP
Battery 12 V – 9 Ah
1
Wiring Harness (with push buttons)
1
Push Buttons Support Bracket
1
Battery Support
1
Battery fix straps
1
Battery Fixing Clamps
2
H.T. Coil
1
Fixing Clamps
8
Sparkplug NGK BR 10 EG
1
Sparkplug Cap
1
MISCELLANEUOS
Clutch Cover + Accessories
1
Dual-Lock fixing tape
1

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ACCESSORIES
EXHAUST GROUP
COPERCHIO FRIZIONE
INLET SILENCER + FILTER
TILLOTSON CARBURETTOR
SPARKPLUG KIT
CLUTCH COVER + H.T. COIL
PUSH BUTTONS BRACKET
WIRING HARNESS
BATTERY SUPPORT KIT

MAN-072
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ENGINE IDENTIFICATION NUMBER
The engine serial number is marked on the front right part of the clutch side crankcase
(see fig.) The number normally includes 1 letter, followed by 2 digits numbers, “AU” and
2 other digits numbers (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 Engine Serial Number and to the engine model.

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2- 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.
2.1- INSTALLATION SKETCH OF THE ENGINE ON THE CHASSIS

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2.2- EXHAUST MANIFOLD INSTALLATION
NOTE:
THE ENGINE IS SUPPLIED WITH AN EXHAUST CARD BOARD COVER TO PROTECT THE INTERNAL PARTS.
THE EXHAUST GASKET AND STUD BOLTS ARE ALREADY MOUNTED.
REMOVE THE NUTS AND THE EXHAUST CARD
BOARD COVER.
MAKE SURE THAT THE EXHAUST GASKET IS IN
SEAT AND INSTALL THE EXHAUST MANIFOLD.
(SEE FIG. 1)
INSERT THE 2 ELASTIC WASHERS 8mm
SUGGESTION:
PUT THE ENGINE IN HORIZONTAL POSITION
AND PLACE THE WASHERS IN THEIR SEAT.
HELP YOURSELF WITH A SCREWDRIVER.
INSTALL 2 COLOMN NUTS.
TIGHTEN TO 18 ÷ 22 Nm.
SUGGESTION:
EASIER TIGHTENING (as per Fig. 2) WITH A
REDUCED EXTERNAL DIAMETER SOCKET
WRENCH OR WITH AN OPEN WRENCH.
12 POINT ELBOWED WRENCH 13 mm (or 13mm OPEN WRENCH)
Fig.1
Fig.2

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2.3- INSTALLATION CARBURETTOR
INSTALL THE GAS CABLE CLAMP ON THE
SUPPORT
(SEE FIG. 5)
12 POINT WRENCH 10mm
REMOVE THE 2 3.5mm SCREWS ON THE CARB.
PUMP (IN CORRESPONDENCE OF THE
THROTTLE LEVER).
(SEE FIG. 6)
SCREWDRIVER 4.8 mm / Torx T20
INSTALL THE SUPPORT BRACKET AND THE TWO
SCREWS.
SCREWDRIVER 4.8 mm / Torx T20
(SEE FIG. 7)
INSTALL THE INTAKE SILENCER SUPPORT
(2x SCREWS M5x10.)
(ALLEN WRENCH 3 mm)
(SEE FIG. 8)
POSITIONING CARBURETTOR
REMOVE THE 2 M6 NUTS.
REMOVE THE PLASTIC PROTECTION
PLUG
LEAVE THE GASKET ON THE ENGINE
AND INSTALL IN THIS WAY (SEE FIG.9):
- CARBURETTOR
TIGHTEN THE CARBURETTOR M6 NUTS AT 6
÷ 10 Nm.
Fig.5
Fig.9
Fig.6
Fig.7
Fig.8

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FINAL STEP - AFTER THE COMPLETE
INSTALLATION OF THE ENGINE ON THE
CHASSIS.
CONNECT THE FUEL FEED HOSE TO THE
INLET FITTING ON THE CARBURETTOR CAP.
(SEE FIG. 10)
2.4- PREPARATION AND INSTALLATON OF THE ENGINE-MOUNT
NOTE: ALL THE DIMENSIONS IN MILLIMETERS
DRILL 4 HOLES (DIAM. 8.25÷8.5mm) IN THE ENGINE-MOUNT .
Fig.10
MOTOR MOUNT HORIZONTAL VIEW

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2.5
INSTALL THE ENGINE ON THE
CHASSIS
POSITION THE ENGINE ON THE 2 OUTSIDE
MAIN RAILS AND FIX THE MOTOR-MOUNT WITH
THE TWO CLAMPS.
(SEE FIG.11)
SUGGESTION:
NEVER TORQUE COMPLETELY THE CLAMPS
UNTIL THE CHAIN IS INSTALLED AND PROPERLY
ALIGNED.
CHECK THE ALIGNMENT OF THE ENGINE
SPROCKET AND THE AXLE SPROCKET WITH A
STRAIGHT EDGE.
(SEE FIG. 12).
INSTALL THE CHAIN (PITCH: 7.775).
(SEE FIG. 13)
MOVE THE ENGINE ON THE RAILS TO ADJUST
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)
COMPLETELY TIGHTEN THE ENGINE MOUNT
SCREWS.
Fig.11
Fig.12
Fig.13
Fig.14
15mm

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2.6
INSTALL THE CLUTCH COVER WITH
H.T. COIL
ALLEN WRENCH 5 mm
REMOVED THE 3 SCREWS TCEI M6x30 FROM
THE CRANKCASE (SEE FIG. 15) AND INSTALL THE
CLUTCH COVER WITH THE H.T. COIL.
(SEE FIG.16)
TIGHTEN THE 3 SCREW 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.
Fig.15
Fig.16

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2.7- ELECTRICAL CONNECTIONS
(refer to the attached electrical scheme)
NOTE:
FOR A CORRECT INSTALLATION FOLLOW
THE UNDER SHOWN INSTRUCTIONS.
INSERT BATTERY FIXING STRIPE IN THE
DEDICATED SLOTS.
(SEE FIG. 17)
PLACE THE BATTERY SUPPORT CLAMPS ON
THE CHASSIS TUBE, FIX THEM THROUGH THE
SPECIFIC SCREWS ON THE SUPPORT PIPES
(SCREW TE M6x25 – SEE FIG. 18). JUST
TIGHTEN A LITTLE TO KEEP THEM IN PLACE
ON THE CHASSIS.
(HEXAGONAL MALE KEY 5mm)
PLACE THE BATTERY SUPPORT, THE PUSH
BUTTONS BRACKET BETWEEN THE CLAMP
AND THE BATTERY SUPPORT, (SEE FIG. 19),
THEN TIGHTEN THE COMPONENTS WITH A
10mm SOCKET WRENCH.
AFTER TIGHTENING THE BATTERY SUPPORT
UPPER SCREW, COMPLETELY TIGHTEN ALSO
THE CLAMPS SCREWS.
(SOCKET WRENCH 10mm)
TROQUE THE SCREWS AT 8 ÷ 10 Nm
(ALLEN WRENCH 5mm)
TORQUE THE SCREWS AT 8 ÷ 10 Nm
(SEE FIG. 19 and 20)
THE BOX MUST BE FIXED WITH AT LEAST ONE
SCREW FOR EACH CLAMP.
FIX WITH MORE SCREWS DEPENDING ON
CHASSIS.
NOTE:
THE DIFFERENT HOLES ON THE BATTERY
SUPPORT AND ON THE BRACKET, ALLOW TO
ADAPT THE SYSTEM TO EVERY CHASSIS.
Fig.17
Fig.18
Fig.19
Fig.20

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PLACE THE STARTER BUTTON IN THE PROPER
HOUSING AND FIX IT THROUGH THE
PROVIDED NUT.
(SEE FIG.21)
FIX AND PLACE THE BUTTON WITH THE
FASTON ORIENTED AS IN THE FIGURE:
PASS THE CABLE WITH THE BUTTONS
TERMINALS IN THE BRACKET, CONNECT THE
2 FASTONS TO THE STARTER BUTTON AND
TIGHTEN THE STOP RED BUTTON WITH THE
PROVIDED NUT (SEE FIG. 22).
NOTE:
THE 2 START BUTTON FASTONS CAN BE
INVERTED, THIS DOES NOT CAUSE
WORKING PROBLEMS.
CONNECT THE BATTERY CABLES TO THE
FASTONS AND TIGHTEN THE STRAP ON THE
CABLES.
(SEE FIG. 23)
CONNECT THE STARTER MOTOR CABLE TO
THE CONNECTOR OF THE CABLES ADAPTER.
(SEE FIG.24)
ATTENTION:
MAKE SURE THAT THE LOCKING OF THE
TWO CONNECTORS IS MADE PROPERLY TO
ENSURE THE GOOD CONTACT OF THE
TERMINALS.
CONNECT THE ADAPTER TO THE CABLES
CONNECTOR.
(SEE FIG.25)
THE 2ND ADAPTER TERMINAL MUST BE
CONNECTED TO THE GROUND.
Fig.21
Fig.22
Fig.23
Fig.24
Fig.25

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FIX THE KIT CABLES THROUGH A STRAP
ACCORDING TO THE CHASSIS AND THE
NEED.
(SEE FIG.26)
CONNECT THE SUPERSEAL 4 WAYS MALE
FASTON CONNECTOR TO THE FEMALE
CONNECTOR OF THE STOP CABLE.
(SEE FIG.27)
CONNECT THE MALE FASTON OF THE STOP
CABLE TO THE FEMALE FASTON
CONNECTOR OF THE INGNITION.
(SEE FIG. 28)
CONNECT THE FEMALE FASTON OF THE
INGNITION CABLE ON THE H.T. MALE
FASTON.
(SEE FIG.29)
SCREW THE SPARK PLUG CAP ON THE COIL
HIGH VOLTAGE CABLE.
(SEE FIG. 30)
FIX THE CUP ON THE A.T. CABLE THROUGH
A PLASTIC STRAP (SEE FIG. 31).
MOUNT THE SPARK PLUG PROVIDED
WITH THE ENGINE
TORQUE AT 20 ÷ 26 Nm
ASSEMBLY THE CUP ON THE SPARK
PLUG.
Fig.26
Fig.27
Fig.28
Fig.29
Fig.31
Fig.37
Fig.30

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2.8
ASSEMBLY OF THE
INTAKE SILENCER
MAKE SURE THAT THE INTAKE SILENCER IS
POSITIONED WITH THE HOLES UPSIDE AND
THAT THEY ARE NOT OBSTRUCTED.
TIGHTEN THE CLAMP ON THE INLET
SILENCER SUPPORT ON THE CARBURETTOR
AND FIX THE INLET SILENCER WITH THE
DEDICATED CLAMP ON THE CHASSIS TUBE.
(SEE FIG. 32-33)
2.9
ASSEMBLY OF THE EXHAUST
SYSTEM
NOTE:
SEE SECTION 3.8 FOR THE WARNINGS ON EXHAUST SYSTEM.
ASSEMBLY THE EXHAUST SILENCER ON THE
EXHAUST MANIFOLD PREVIOUSLY
MOUNTED ON THE CYLINDER AND FIX IT
WITH THE PROVIDED SPECIFIC SPRINGS.
(SEE FIG.34).
FIX THE SILENCER ON THE CRADLE SUPPORT
OF THE CHASSIS.
THE ENGINE IS NOW READY TO START
Fig.33
Fig.34
Fig.32

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3.1- MIXTURE OIL AND FUEL
Use unleaded Premium gasoline 95 RON, mixed with oil at 5% (20:1).
Use oils containing castor’s oil that guarantees an optimized lubrication at high
temperature.
As on the other hand, castor oils create gummy residues that give origin to carbon
deposits causing incrustations, it is necessary to check and clean the piston and the
head at least every 5 ÷10 hours.
Recommended oils :
WLADOIL RACING K2T
SHELL ADVANCE RACING M
ELF HTX 909
ERG K KART FORMULA
Once the tank has been filled, make sure that the fuel flows to the carburettor before
starting the engine.
Avoid pump fuel to the carburettor by operating the electric starter, as it causes a
useless battery discharge.
SUGGESTION:
Remove the fuel tube on the carburettor and the breather pipe of the recovery tank
breather and blow into the breather pipe till the fuel comes out from the tube on the
carburettor. Make sure that there are no air bubbles into the tube. Connect the tube on
the carburetor and on the breather.

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3.2- CARBURETTOR SETTING
1 T.O.*
RICH LEAN
1 ¼ T.O. ¾ T.O.
1 ½ T.O.
* T.O. = TURNS OPEN
Generally the correct settng of the carburettor screws is the following :
L (close the screw completely and then open): 2 and 05' T.O.
H (close the screw completely and then open): 50' T.O.
According to various factors as altitude and environmental temperature, it might be necessary to adjust the
carburettor settings to optimize the engine performance.
ATTENTION :
- Never lean excessively the mixture, the engine may overheat and seize up
- Never force the screws H and L completely. This may damage the screws housing and make the
carburetor unusable.
- The carburettor setting must be made on warm engine.
(H)
Torque the screw completely
and open at:
50' T.O.
(L)
Torque the screw completely and open
approx. at 2 and 05' T.O.
(I)
Turn the screw till to the
contact with throttle lever and
screw futher of 1 ½ T.O.
Start the engine and warm it. If the if RPM is
too high, set the screw l counterclockwise,
untill the clutch is disengaged.
If RPM
decreases
Unscrew counterclockwise
untill max RPM is reached.
Unscrew just enough wich
allows to reach the idle.
(L)
Counterclockwise setting
If RPM
increases
Continue ad avvitare in senso
orario fintanto che non si
raggiunge il massimo regime
possibile. Svitare di quel tanto
che permetta un minimo
tendente al ricco.
Engine is now idling, turns at max gettable
RPM and will be tending on rich.
Adjust counterclockwise L screw until to
2.000 ÷ 2.500 rpm is reached.
Check again L screw for an optimal setting
The H screw setting can be only in working.
Set H screw to achieve the besT possible
RPM on straight. Set clockwise to increase
RPM and counterclockwise to reduce RPM.
Set L screw on rich of 1/8 ÷
¼ T.O.
Bad
acceleration
Go back to the idle and check acceleration
for a quick response and smooth pick-up.
Good
acceleration
The engine is ready
SCREW ( I )
OF MINIMUM
SETTING
SCREW ( L ) LOW SPEED MIXTURE
SCREW ( H ) HIGH SPEED MIXTURE
MMMIXTURESCREW

MAN-072
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3.3- STARTING AND STOPPING THE ENGINE
The engine start is achieved by pushing the black rubber button on the bracket.
If the engine does not start, stop and try again.
If the engine does not start within 5 seconds (check that gasoline flows to the carburettor),
stop the procedure and try after about 15 seconds. Short and frequent tries are better
than long ones.
In case the engine can't be started, refer to the Sec. 4.6 "Troubleshooting”.
Stop the engine by pressing the red button on the bracket.
Keep the stop button pressed until the engine is completely stopped.
3.4- ENGINE RUNNING-IN
The running-in must be made following a few basic rules :
1. Carburation setting. Start with basic setting on the rich side.
2. Warm the engine gradually for 5 minutes, driving some laps at low speed, smoothly
closing and opening the accelerator (if a tachometer is installed, never exceed
9.000 ÷ 10.000 RPM). Never keep the same RPM for a long time but alternate the
speed.
3. Gradually increase the vehicle speed for about 5 minutes (with ¾ throttle opening).
Never keep the same RPM for a long time but to alternate it.
4. Increase the speed driving some laps, for about 5 minutes (with acceleretor fully
opened on circuit twisty parts and enrich the carburation at half straight (cover with
the hand the inlet hole on the intake silencer for an istant, keeping the throttle open).
WARNING :
Once the running-in is over, with cold engine, check the torque of exhaust pipe nuts as
during the 1st running-in, the nuts can loosen (refer to the attached table).
3.5- INLET SILENCER
Make sure that the inlet holes of the inlet silencer are towards the upper side and they
are not covered. Make sure that the fixing strapis not loosen and that the inlet silencer is
well fastened to the chassis through the specific strap.
Occasionally, check the presence of oil deposits in the inlet silencer. If necessary,
remove the manifold with filter and clean the inside with gasoline or a diluent.
3.6- EXHAUST SYSTEM WARNINGS
Make sure that the silencer fixing springs are well hooked. In case of damage replace
the broken springs. Never race the kart without the two spring well hooked, as the
silencer could vibrate under the standard limits.
It is recommended to open the exhaust pipe end every 10 15 hours and make sure that
the holes on the counter cone are not obstructed by incrustation.

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3.7- EXHAUST GAS TEMPERATURE PROBE
The exhaust muffler is not provided with a temperature probe lodgment. If necessary, it
is possible to install the probe support and as indicated in the figure.
Whenever you wish to employ the probe, please proceed as shown in the figure below.
3.8- CENTRIFUGAL CLUTCH
The engine has a low maintenance dry centrifugal clutch. The following prescriptions, if
carefully followed, will allow a clutch longlife.
When starting the engine, make sure that the brake pedal is fully pressed to avoid any
sudden accelerations.
WARNING:
Once the engine is started, absolutely avoid useless accelerations (glazed of the friction and/or
skids) which can overheat and deteriorate the clutch group before time. Grease the chain before
each session. Check the engine sprocket, after each test or race and replace it, if necessary.
A bad alignment of the engine sprocket with the axle sprocket or chain grease lack can
irreparably damage the sprocket.
When it is necessary to check the clutch?:
Every 5 hours of standard use.
When metallic noises from the clutch are heard.
If the kart dragging speed exceeds 6.000 RPM.
When the clutch has overheated (presence of smoke or smell of burning).
Remove the clutch cover and the clutch drum to check the clutch.
When it is necessary to replace the clutch?:
whenever the thickness of the friction materiali s lower than 1.5mm on “point A” of
the figure, if the body diameter is lower than 83mm, or when is very rough (wear
and deterioration of the friction material due to overheating).
WARNING:
In case the friction material is fully worn out and there has been a prolonged contact between
the clucth body and clutch drum, it also necessary to replace the clutch drum.
A
A
A
drill exhaust Ø4.2 for cylindrical probe
drill exhaust Ø4.2 and thread M5 for threaded probe

MAN-072
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3.9- INSTRUCTIONS FOR THE DISASSEMBLY / ASSEMBLY OF THE CLUTCH GROUP
WARNING :
The following operations can be made by a skilled mechanic, with the proper tools
shown in the text ; otherwise, it is necessaty to apply to an Authorized Service Center.
Refer to the following drawing during the different operations.
OPERATIONS
TOOLS
Clutch disassembly
1. Remove the clutch cover (3 screws TCEI M6).
Allen wrench 5mm – T type
2. Remove the bendix cover and place the starter wheel
locking tool.
Starter wheel locking tool : S 884
3. Remove the retainer nut (1 nut M10).
Ring wrench 17 mm
4. Remove the external washer, the complete drum with
roller cage, the internal washer.
5. With the starter wheel locking tool in place, remove
the 20x1clutch hub nut.
WARNING: unscrew clockwise as the nut has left-
hand thread
Starter wheel locking tool: S 884
Allen wrench 30 mm
6. Remove the clutch hub and the starter wheel from the
crankshaft through clutch puller.
Clutch puller : ATT.026
Allen wrench 12mm
7. Remove the starter wheel (3 screws M6 TCEI)
 Allen wrench 5mm – T type
1 Drum retaining nut 6 Sprocket 11 Clutch body
2 External washer 7 Clutch drum 12 Starter wheel
3 Roller cage 8 Internal washer
4 O Ring 9 Loocking nut
5 Screw 10 Screw
1
2
3
4
6
7
10
8
5
9
11
12