IAME Parilla X30 125cc RL Bedienungsanleitung

28/09/05 MAN-044 /A

OVERHAUL MANUAL

28/09/05 MAN-044 /A

INDEX

Page

1. - PARILLA X30 125cc RL – TaG ENGINE DISASSEMBLY 1

2. - CRANKSHAFT DISASSEMBLY/ ASSEMBLY 10

2.1- CRANKSHAFT DISASSEMBLY 10

2.2- CRANKSHAFT ASSEMBLY 12

3. - PARILLA X30 125cc RL – TaG ENGINE ASSEMBLY 15

ATTACHMENTS

- FASTENER TORQUE VALUES

- CROSS PATTERN LOCKING ORDER ON CRANKCASE

- MAIN PRESCRIPTIONS

- CON-ROD BIG AND SMALL END BEARING TOLERANCES

- GEAR INSTALLATION - RECOMMENDATIONS

-LIST OF OVERHAUL TOOLS

-Table for wear evaluation on Bearings/ Halfcrankshafts

-BENCH ENGINE FIXING TOOL – Drawing

MAN-044/A

1 – X30 125cc RL – TaG ENGINE DISASSEMBLY

OPERATIONS PICTURES

DISCHARGE OIL FROM THE ENGINE

- UNSCREW THE OIL LEVEL PLUG

(see Fig.1).

(14mm socket wrench)

- TILT THE ENGINE TO DISCHARGE OIL

(see Fig.2).

FIX THE ENGINE ON THE BENCH VICE

- SCREW ON N°2 SCREWS M8x60 ON THE

CRANKCASE

BENCH TOOL (see attached drawing )

REMOVE THE EXHAUST HEADER

- UNSCREW N°2 NUTS M8 (see Fig. 3).

(13mm SOCKET WRENCH)

- REMOVE N°2 WASHERS

- REMOVE THE EXHAUST GASKET

Fig.3

MAN-044/A

REMOVE THE IGNITION

- REMOVE THE STATOR

UNSCREW N°4 ALLEN SCREWS M5x25 (see

Fig.4)

(4mm ALLEN WRENCH - T TYPE)

- REMOVE SPARKPLUG AND INSTALL THE

THE PISTON FITTING (P.N. 10271) TO

PREVENT THE CRANKSHAFT FROM

TURNING (see Fig.5).

- REMOVE THE NUT M10 AND WASHER

(see Fig.6).

(17mm SOCKET WRENCH)

- EXTRACT THE ROTOR (see Fig.7).

(USE A SCREWDRIVER IF NECESSARY)

REMOVE KEY FROM SHAFT

Fig.4

Fig.5

Fig.6

Fig.7

MAN-044/A

REMOVE THE GEAR BOX COVER

- UNSCREW N°7 ALLEN SCREWS M6x16

(see Fig.8).

(5mm ALLEN WRENCH - T TYPE)

- REMOVE COVER AND WASHER

(USE A PLASTIC MALLET IF NECESSARY)

(see Fig.9).

REMOVE GEARS

- REMOVE RETAINING RINGS FROM THE

CRANKSHAFT AND BALANCE SHAFT

(see Fig.10).

(PLIERS FOR RETAINING RINGS)

- REMOVE GEAR ON THE CRANKSHAFT

(see Fig.11).

ATTENTION:

MARK THE GEAR FOR IDENTIFICATION

WHEN REASSEMBLING

NOTE:

IN THE ENGINES MNUFACTURED AFTER

SEPTEMBER ’05, THE FIXING OF THE GEAR

ON THE CRANKSHAFT IS MADE BY A

SPACER WITH AN “OR” WHICH IS PUSHED

AGAINST GEAR BY THE IGNITION ROTOR

(see drawing).

Fig.8

Fig.9

Fig.10

Fig.11

MAN-044/A

- REMOVE GEAR FROM THE BALANCE

SHAFT

(see Fig.12).

(USE A SCREWDRIVER IF NECESSARY) .

REMOVE ELECTRIC STARTER

- UNSCREW N°2 ALLEN SCREWS M6x35

(see Fig.13).

( 5mm ALLEN WRENCH – T TYPE )

- REMOVE STARTER (see Fig.14).

NOTE:

IN THE ENGINES MNUFACTURED AFTER

SEPTEMBER ’05, THE STARTER CAN ALSO

BE REMOVED WITHOUT TAKING AWAY

THE GEARS COVER BUT SIMPLY BY

REMOVING THE CLAMP OF THE COVER

(see drawing).

REMOVE CLUTCH

- DISCONNECT THE GROUND CABLE FROM

THE CRANKCASE

UNSCREW THE ALLEN SCREW M6x12

(see Fig.15).

(5mm ALLEN WRENCH-T TYPE)

Fig.12

Fig.13

Fig.14

Fig.15

MAN-044/A

- REMOVE CLUTCH COVER

UNSCREW N°3 ALLEN SCREWS M6x25

(see Fig. 16).

(5mm ALLEN WRENCH – T TYPE)

- REMOVE THE LOCKING NUT M10 FROM

CLUTCH DRUM (see Fig.17).

(17mm SOCKET WRENCH )

NOTE:

MAKE SURE THAT THE PISTON STOP TOOL

IS INSTALLED (P.N. 10271)

- REMOVE OUTER WASHER, CLUTCH

DRUM, ROLLER CAGE AND INNER

WASHER

- REMOVE THE PISTON STOP TOOL

AND WITH THE CLUTCH LOCKING

WRENCH (P.N. 10270), REMOVE THE

LOCKING NUT M20 FROM CLUTCH BODY

(see Fig.18).

( 30 mm HEXAGON RING WRENCH)

ATTENTION:

TURN CLOCKWISE AS NUT HAS LEFT

THREAD.

- REMOVE CLUTCH BODY AND STARTING

RING FROM THE CRANKSHAFT WITH THE

CLUTCH DISASSEMBLY TOOL

(P.N. 10272-C) (see Fig.19).

(12mm ALLEN WRENCH

(27mm WRENCH)

Fig.16

Fig.17

Fig.18

Fig.19

MAN-044/A

- REMOVE STARTING RING

FROM CLUTCH BODY

UNSCREW N°3 SCREWS M6x12 (see

Fig.20).

(10mm SOCKET WRENCH)

REMOVE STARTER COUNTERSHAFT

- REMOVE STARTER COUNTERSHAFT

COVER

UNSCREW N°3 ALLEN SCREWS M6x25 (see

Fig.21).

( 5mm ALLEN WRENCH – T TYPE )

- EXTRACT STARTER COUNTERSHAFT

(see Fig.22).

10.

REMOVE CARB. INLET CONVEYOR

- UNSCREW N°4 ALLEN SCREWS M6x25

(see Fig.23).

(5mm ALLEN WRENCH –T TYPE )

- REMOVE OUTER GASKET FROM

CONVEYOR

Fig.20

Fig.21

Fig.22

Fig.23

MAN-044/A

- REMOVE REED GROUP

(see Fig.24).

- REMOVE INNER WASHER FROM

REED GROUP

11.

REMOVE CYLINDER HEAD

- UNLOOSE N°4 NUTS M8 BY HALF TURN

(CROSS PATTERN DISASSEMBLY),

REMOVE NUTS

(see Fig.25).

( 13mm HEXAGON RING WRENCH)

- REMOVE WASHERS

12.

REMOVE CYLINDER

(see Fig.26).

- REMOVE CYLINDER BASE GASKET

13.

REMOVE PISTON

- REMOVE CIRCLIPS FROM PISTON

(see Fig.27).

(SCREWDRIVER WITH ROUND EDGES)

ATTENTION:

DO NOT SCRATCH PISTON AND CIRCLIP

SEATS.

Fig.24

Fig.25

Fig.26

Fig.27

MAN-044/A

- REMOVE PISTON PIN WITH SPECIAL

PISTON PUNCH (P.N. 10200)

(see Fig.28).

- REMOVE PISTON

- REMOVE ROLLER CAGE

14.

OPEN CRANKCASE

- UNSCREW N°10 ALLEN SCREWS M6x45

(see Fig.29).

(5mm ALLEN WRENCH – T TYPE)

- OPEN CRANKCASE WITH A PLASTIC

MALLET

(see Fig.30).

(PREVENT THE CRANKSHAFT FROM

FALLING)

15.

REMOVE CRANKSHAFT AND BALANCE

SHAFT

(see Fig.31).

Fig.28

Fig.29

Fig.30

Fig.31

Dieses Handbuch passt für folgende Modelle

Inhaltsverzeichnis

Andere IAME Motor Handbücher

IAME

IAME Parilla LEOPARD Betriebsanleitung

IAME

IAME REEDSTER 125cc Betriebsanleitung

IAME

IAME MINI SWIFT 60CC - USA Bedienungsanleitung

IAME

IAME REEDJET 100cc Bedienungsanleitung

IAME

IAME EASY-KART 2003 Montageanleitung

IAME

IAME X30 SUPER 175CC Installationsanleitung

IAME

IAME Parilla MINI SWIFT Bedienungsanleitung

IAME

IAME Parilla SCREAMER KZ1 Installationsanleitung

IAME

IAME GR-3 040/EM/12 Bedienungsanleitung

IAME

IAME Parilla Leopard TaG Series Betriebsanleitung

IAME

IAME Parilla Norswift 60cc Montageanleitung

IAME

IAME Parilla Reedster 125cc Bedienungsanleitung

IAME

IAME ReedJet AUS 100cc-TaG Bedienungsanleitung

IAME

IAME Parilla x30 125cc RL-TaG Betriebsanleitung

IAME

IAME Parilla Norswift 60cc Betriebsanleitung

IAME

IAME 125cc LEOPARD TaG Montageanleitung

IAME

IAME 125cc LEOPARD TaG Montageanleitung

IAME

IAME X30 125cc RL - TaG Betriebsanleitung

IAME

IAME Parilla Norswift 60cc Bedienungsanleitung

IAME

IAME 125cc LEOPARD TaG Montageanleitung

IAME

IAME M1 60cc Montageanleitung

Beliebte Motor Handbücher anderer Marken

Rotax

Rotax 125 senior MAX evo Bedienungsanleitung

Kohler

Kohler K361 Bedienungsanleitung

MTD

MTD OHV Series Bedienungsanleitung

Kohler

Kohler COMMAND CH18-745 Bedienungsanleitung

Mercury

Mercury D4.2L D-Tronic Bedienungsanleitung

Selve

Selve SE Plus-RC Series Bedienungsanleitung

Perkins

Perkins 1206E-E66TA Bedienungsanleitung

Skov

Skov DA 174 Handbuch

Rossi

Rossi TX11 Series Bedienungsanleitung

Siemens

Siemens SIMOTICS T-1FW3 Merkblatt

AL-KO

AL-KO PRO 350 Bedienungsanleitung

MTU

MTU 12 V 4000 Lx4 Bedienungsanleitung

Nanni

Nanni N3.30 Gebrauchsanweisung

Nanni

Nanni N5.160 CR2 Bedienungsanleitung

KSB

KSB SuPreme Series Montageanleitung

Hiwin

Hiwin EM1 Series Bedienungsanleitung

Rotax

Rotax 912 i series Betriebsanleitung

Siemens

Siemens SIMOTICS XP 1MB1 Bedienungsanleitung