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Related Manuals for IAME M1 60cc
Summary of Contents for IAME M1 60cc
- Page 1 M1 60cc ASSEMBLY INSTRUCTIONS AND USER MANUAL MAN-088...
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Page 2: Table Of Contents
INDEX PAGE General description of engine Characteristics of the engine – Operational limits Contents of packing Engine Identification Number 3- Preparation and installation of the engine on the chassis Installation of thermal protection safety cover 3.2 Exhaust Header Assembly Preparation and installation of the motor-mount 3.4 Inlet system installation 3.5 Install the engine on the chassis 3.6 Install the clutch cover... -
Page 3: General Description Of Engine
GENERAL DESCRIPTION OF ENGINE This engine is for propaedeutic series and for very young drivers and has been specifically designed and developed for powering of kart, either for racing purposes and hobby, but always on closed tracks. During the design phase has been inspired to the technical solutions already adopted for high-performance engines kart, to its simplicity of installation and use, related to a parsimonious maintenance, in order to ensure the maximum durability and reliability of the components, subject to compliance with the operational limits. -
Page 4: 1- Contents Of Packing
OPERATIONAL LIMITS: Max. RPM / 1’: 12.500 RPM (Without limiter) 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:... -
Page 5: 2- Engine Identification Number
SPARK PLUG NGK EXHAUST GROUP CYLINDER & CYLINDER HEAD THERMAL PROTECTION SAFETY COVER CLUTCH COVER INTAKE GROUP + TILLOTSON HS-323A CARBURETTOR INTAKE SILENCER + FIXING CLAMP COIL WITH SPARK PLUG CAP COIL-SWITCH CABLE 2- ENGINE IDENTIFICATION NUMBER MAN-88 – UK... -
Page 6: 3- Preparation And Installation Of The Engine On The Chassis
NOTE: In case of need for spare parts and when contacting the IAME Support Centers, please always supply to the Engine Identification Number and model. 3- PREPARATION AND INSTALLATION OF THE ENGINE ON THE CHASSIS... -
Page 7: Installation Of Thermal Protection Safety Cover
NOTE: In case the engine is supplied already assembled on to 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. -
Page 8: Exhaust Header Assembly
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. - REMOVE THE EXHAUST COVER GASKET. - INSTALL THE SCREWS AND THE WASHER ON THE SAFETY COVER OF THE MUFFLER. n°2 M6x95 n°1 M6x12 n°3 WASHER Ø24/Ø6.6... - Page 9 -POSITION N°2 EXHAUST GASKET AND N°1 THERMAL SPACER RESTRICTOR (SEE FIG). - INSTALL THE MUFFLER WITH ITS SAFETY COVER ON THE ENGINE AND TIGHTEN (BUT NOT DEFINITELY) ALL SCREW OF FIXING. WHEN THE POSITION OF THE ALL COMPONENTS IS CORRECT TIGHTEN DEFINITELY ALL SCREWS. N°3 SCREWS WITH 5 mm ALLEN WRENCH TORQUE THE 3 SCREWS AT 8 ÷...
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Page 10: Preparation And Installation Of The Motor-Mount
PREPARATION AND INSTALLATION OF THE MOTOR-MOUNT -DRILL 4 HOLES (DIAM. 8.5mm) INTO THE MOTOR-MOUNT.( ALL THE DIMENSIONS ARE IN MILLIMETERS) MOTOR-MOUNT HORIZONTAL VIEW - 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). -
Page 11: 3.4 Inlet System Installation
3.4 INLET SYSTEM INSTALLATION Pre assembling: N°2 SCREWS M6x30 INTO THE INLET SPACER AND TAKE A POSITION OF THE INLET GASKET ENGINE SIDE AS IN PICTURE. Fig.6 -POSITION THE PRE-ASSEMBLED INLET SPACER TO THE ENGINE INLET, COMING TO THE TIGHTEN IN MANUAL WAY FOR FIXING TEMPORARY THE SPACER. - Page 12 - POSITION THE FIXING CLAMP TO INLET BOX. - INSTALL THE INLET BOX TO THE INLET SUPPORT AND TIGHTEN WITH THE FLATHEAD OR PHILLIPS SCREWDRIVER. - CONNECT BY APPROPRIATE PIPE; THE INTAKE PRESSURE MANIFOLD ON THE CARBURETTOR AND THE INTAKE PRESSURE MANIFOLD ON THE CRANKCASE.
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Page 13: Install The Engine On The Chassis
INSTALL ENGINE ON THE CHASSIS - POSITION THE ENGINE ON THE 2 MAIN RAILS AND FIX THE MOTOR-MOUNT WITH THE TWO CLAMPS. SUGGESTION: NEVER TORQUE COMPLETELY THE CLAMPS UNTIL THE CHAIN IS INSTALLED AND PROPERLY ALIGNED. - CHECK ALIGNMENT ENGINE SPROCKET AND THE AXLE SPROCKET WITH A STRAIGHT EDGE. -
Page 14: Install The Clutch Cover
INSTALL THE CLUTCH COVER -REMOVE THE 3 SCREWS M6x30 ON THE CRANKCASE (SEE FIG. 18) AND INSTALL THE CLUTCH COVER. TORQUE THE 3 SCREWS AT 8 ÷ 10 Nm (70 ÷ 90 in-lb) 5 mm ALLEN WRENCH ELECTRICAL CONNECTION -CONNECT THE COIL CABLE (SMALL ONE) TO THE TERMINAL ON THE COIL. -
Page 15: 4- Gasoline And Oil
4- GASOLINE AND OIL Use leaded or unleaded gasoline with minimum 95 ROM, mixed with oil at 3% (33:1). Use oils containing ricinoleate which ensures optimum lubrication at high temperatures As on the other hand use oils containing ricinoleate 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 cylinder head. -
Page 16: 5- Tillotson Hs-323A Carburettor Adjustament
5-TILLOTSON HS-323A CARBURETTOR ADJUSTEMENT ( I ) TROTTLE SPEED SCREW ( L ) LOW SPEED FUEL MIXTUREREGIMI ( H ) HIGH SPEED FUEL MIXTURE REGIMI LEAN RICHE 1 T.O. ¾ ¼ T.O. T.O. ½ T.O. = TURNS OPEN T.O. Normally the correct setting of the mixture screws, after engine run-in, is the following: §... -
Page 17: 6- Starting And Stopping The Engine
6- STARTING AND STOPPING THE ENGINE The engine is started by pulling the handle that uncoils the rope. The rope rotates the pulley that engages the ignition flywheel connected to the crankshaft. This action, made with the appropriate energy and eventually repeated if needed, starts the engine. First of all, the switch located on the right side of the engine and mounted on the bracket attached to the clutch cover, must be turned on the “... -
Page 18: 9- Recommendations On The Exhaust System
9- RECOMMENDATIONS ON THE EXHAUST SYSTEM Always make sure that the screws are well tighten to the manifold and in place. Never race the kart without all screws tighten, as otherwise the exhaust pipe could vibrate beyond control. Every 10 hours, cleaned the exhaust muffler and make sure that the hole on the rear are not plugged. -
Page 19: 11- Instructions For The Disassembly / Assembly Of The Clutch
11- INSTRUCTIONS FOR THE DISASSEMBLY / ASSEMBLY OF THE CLUTCH ATTENTION: The following operations must be performed by a skilled mechanic under the condition 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. - Page 20 Before assembling the clutch, degrease with diluent the shaft taper, the conical hole on the clutch body, the clutch drum. Clutch reassembly TOOLS 1. Insert key on shaft. 2. Install clutch body and cone safety washer on shaft. 3. Install the M16x1 nut using the clutch wrench. Clutch wrench CH 24 §...
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Page 21: 12- Spark-Plug Thermal Degree
12- SPARK-PLUG THERMAL DEGREE The engine is supplied with a standard NGK BR9EG 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 possibile 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. -
Page 22: 13- Choice Of The Best Sprocket Ratio
The operating limit for the engine is 12.500 RPM. ATTENTION: Never exceed the above limit. No obligation of IAME exists in case the above limit is exceed. 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. - Page 23 Use spark plug 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.
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Page 24: 14- Scheduled Maintenance
14- SCHEDULED MAINTENANCE Following some simple maintenance standards will allow to perform more reliably and guarantee a longer engine life. SCHEDULE COMPONENTS ACTIONS AND COMMENTS Exhaust Check status and fixing Before using Engine sprocket Check wear Check alignment with axle sprocket Engine chain Check wear, tensioning and oil... - Page 25 (so to reach the better performance) or not competitive. IAME suggests to replace the piston any 150lt , or before whenever the clearance between piston and cylinder exceeds 0.12mm .
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Page 26: 16- Troubleshooting
The replacement can be made every 150lt . CONROD BIG END CAGE, CRANKPIN AND MAIN BEARING The replacement can be made every 300lt . MAIN BEARING The replacement can be made every 300lt . CONROD The replacement can be made every 600lt . Anyway it must be replaced whenever the big end hole ovalization exceeds 0.01mm . - Page 27 Below are some common faults, their probable causes and suggested remedy. FAULTS PROBABLE CAUSE REMEDY When pulling the handle don’t start Not turned on the “ ON ” position Turned on the “ ON ” position the the engine the switch switch Bad connections cables Check and restore...
- Page 28 When engine has to remain unoperative for a long period it must be preserved as follows : § Disconnect carburettor and clean it. § 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.