IAME Parilla Reedster 125cc Overhauling Manual

07/11/07 MAN-052

1

OVERHAULING MANUAL

REEDSTER 125cc

versions: F1 - F2 - F3 - F4

21

/01/2009

07/11/07 MAN-052

2

INDEX

Pag

e

1.

-

REEDSTER

125c

c ENGINE DISASSEMBLY

1

2.

-

CRANKSHAFT DISASSEMBLY

/

ASSEMBLY

1

3

2.1

-

CRANKSHAFT DISASSEMBLY

1

3

2.2

-

CRANKSHAFT ASSEMBLY

1

5

3.

-

REEDSTER

125cc

ENGINE ASSEMBLY

1

8

ATTACHMENTS

-

FASTENER TORQUE TABLE

-

CROSS PATTERN LOCKING ORDER ON CRANKCASE

-

MAIN PRESCRIPTIONS

-

CONROD

BIG END

AND SMALL

END

S

TOLERANCE

S

-

OVERHAULING TOOL LIST

-

W

ear

E

valuation

Tab

le

on

Bearings/ Halfcrankshafts

-

Drawing of

f

ixing engine tool

MAN-052

1

1 –REEDSTER 125cc ENGINE DISASSEMBLY

OPERA

T

ION

S

PICTURES

1. DISCHARGING OIL FROM GEARBOX

- UNSCREW THE M6 SCREW FOR

DISCHARGING OIL

(see Fig.1).

(5mm ALLEN WRENCH – T TYPE)

- TILT THE ENGINE TO FACILITATE OIL

DISCHARGINGAND CHECK THAT THE

GEARBOX BREATHER IS FREE AND

(see Fig.2).

2. FIX THE ENGINE ON THE BENCH VICE

- SCREW N°2 SCREWS M8x30 IN THE

CRANKCASE

TOOL FOR BENCH VICE (see attached drawing)

3. REMOVE THE EXHAUST FITTING

- UNSCREW N°4 SCREWS M6x25 (see Fig.3).

(5mm ALLEN WRENCH – T TYPE)

- REMOVE THE N°4 ELASTIC WASHERS

- REMOVE THE EXHAUSTFITTING,

SPACER AND BOTH GASKETS.

Fig.1

Fig.2

Fig.3

MAN-052

2

4. REMOVE THEIGNITION

- REMOVE STATOR

UNSCREW N°3 M5x25 SCREWS (see Fig.4)

(4mm ALLEN WRENCH – T TYPE)

- REMOVE SPARKPLUG AND INSTALL THE

SPECIAL PISTON RETAINER (P.N. 10271)

TO LOCK THE CRANKSHAFT

(see Fig.5).

- REMOVE NUT M12 (see Fig.6).

(17mm SOCKET WRENCH)

- EXTRACT ROTORWITH THE SPECIAL

TOOL ( P.N. ATT-009)

(see Fig.7).

- REMOVE KEY FROMCRANKSHAFT

Fig.4

Fig.5

Fig.6

Fig.7

MAN-052

3

5. DISASSEMBLE GEAR COVER

- UNLOOSE N°2 SCREWS M6 FIXING THE

STARTER CLAMP.

- UNSCREW N°7 ALLEN HEAD SCREWS M6

(see Fig.8).

(5mm ALLEN WRENCH – T TYPE)

- REMOVE COVER AND WASHER

(see Fig.9).

(WITH THE HELP OF A PLASTIC MALLET IF

NECESSARY)

ATTENTION:

PAY ATTENTION NOT TO DAMAGETHE OIL

SEAL LIP

6. REMOVE STARTER

- UNLOOSE N°4 SCREWS M6x35

(see Fig.10).

(5mmALLEN WRENCH -T TYPE )

- REMOVE STARTER

(see Fig.11).

NOTE:

THE STARTER CAN BEREMOVED

WITHOUTTAKING THE GEAR COVER OFF,

BY SIMPLY REMOVING THE COVER CLAMP

(see drawing).

Fig.8

Fig.9

Fig.10

Fig.11

M6x

2

0

M6x20

M6x20 M6x30

M6x

3

0

ATT.: screw,

crankshaft starter side

MAN-052

4

7. REMOVE CLUTCH

- DISASSEMBLE THE CLUTH COVER

UNSCREW N°3 SCREWS M6x25

(see Fig.12).

(5mm ALLEN WRENCH – T TYPE)

- DISCONNECT THE GROUND CABLE FROM

CRANKCASE

UNSCREW M6x12 SCREW (see Fig.13).

(5mm ALLEN WRENCH – T TYPE)

- REMOVE STARTER COUNTERSHAFT

COVER

UNSCREW N°3 SCREWS M6x25

(see Fig.14).

(5mm ALLEN WRENCH – T TYPE)

- REMOVE PISTON RETAINER FROM HEAD

AND INSTALL THE STARTER RING

LOCKING TOOL (P.N. S884).

- REMOVE M10 NUT FIXING THE CLUTCH

DRUM

(see Fig.15).

(17mm SOCKET WRENCH)

- REMOVE THE OUTER WASHER, THE

CLUTCH DRUM, THE ROLLER CAGE

AND THEINNER WASHER

Fig.15

Fig.12

Fig.13

Fig.14

MAN-052

5

- REMOVE THE M20 NUT FIXING THE

CLUTCH BODY (see Fig.16).

(30mm SOCKET WRENCH)

ATTENTION:

TURN CLOCKWISE AS NUT HAS LEFT

THREAD

- REMOVE THE CLUTCH BODY AND THE

STARTING GEAR FROM THE

CRANKSHAFT BY MEANS OF THE CLUTCH

DISASSEMBLY TOOL

(P.N. 10272-C) (seeFig.17).

(19mm and 27mm- SOCKET WRENCHES)

- REMOVE STARTER GEAR FROM THE

CLUTCH BODY

UNSCREW N°3 SCREWS M6x12

(see Fig.18).

(10mm-SOCKET WRENCH)

- REMOVE THE STARTER COUNTERSHAFT

(see Fig.19).

Fig.16

Fig.17

Fig.18

Fig.19

MAN-052

6

8. REMOVE WATER PUMP

- REMOVE PUMP COVER

UNSCREW N°4 SCREWS M6x20 (see

Fig.20).

(5mmALLEN WRENCH – T TYPE)

- REMOVE COVER AND WASHER

(see Fig.21).

- INSTALL THE GEAR LOCKING TOOL

(P.N. ATT-008) (see Fig.22).

- UNSCREW SCREW M5X20 AND REMOVE

PUMP IMPELLER (see Fig.23).

(8mm- SOCKETWRENCH)

Fig.20

Fig.21

Fig.22

Fig.23

MAN-052

7

9. REMOVE GEARS

- REMOVE THE RETAINER RING ON THE

COUNTERSHAFT (see Fig.24).

(PLIERS FOR RETAINER RING)

- REMOVE GEAR ON THE COUNTERSHAFT

(USE THE PULLERP.N. ATT-010 IF

NECESSARY)

- REMOVE CONE SAFETY WASHER

- UNSCREW NUT ON THE CRANKSHAFT

(see Fig.25).

(27mm SOCKET WRENCH)

- REMOVE THE GEAR LOCKING TOOL

- REMOVE GEAR FROM THE CRANKSHAFT

(USE THE PULLER P.N ATT-010,IF

NECESSARY)

(see Fig.26).

(19mmSOCKET WRENCH )

ATTENTION:

MARK THE GEAR WITH A FELT PEN IN

ORDER TO RECOGNIZE IT WHEN RE-

ASSEMBLING.

10. REMOVE COUNTERSHAFT

- REMOVE THE COUNTERSHAFT BEARING

SUPPORT

UNSCREW N° 6 SCREWS M6 (see Fig.27).

(5mm ALLEN WRENCH – T TYPE)

Fig.24

Fig.25

Fig.26

Fig.27

M6x20

M6x60

M6x

6

0

M6x

6

0

M6x

6

0

MAN-052

8

- EXTRACT THE BEARING SUPPORT BY

PUSHING COUNTER CRANKSHAFT FROM

THE SIDE OF THE WATER PUMP

(see Fig.28).

ATTENTION:

PAY ATTENTION NOT TO DAMAGETHE OIL

SEAL LIP

11. REMOVE THE CARB INLETDUCT

- UNSCREW N°4 SCREWS M6x25

(see Fig.29).

(5mm ALLEN WRENCH – T TYPE)

- REMOVE DUCT, REED GROUP AND

WASHERS

(see Fig.30).

12. REMOVE EXHAUST VALVE

(EXCEPT FOR F3 WHICH DOES NOT HAVE

EXHAUST VALVE)

- REMOVE THE STEEL CLIP FROM THE

VALVE (seeFig.31).

Fig.28

Fig.29

Fig.30

Fig.31

MAN-052

9

- REMOVE VALVE COVER AND RETAINING

SPRING

(see Fig.32).

- UNSCREW N° 2SCREWS M6 (see Fig.33).

(5mm ALLEN WRENCH – T TYPE)

- EXTRACT THE VALVE FROM THE

CYLINDER

(vedi Fig.34).

- UNSCREW COMPLETELY THE SLIDE

BY HAND AND REMOVE ITFROMITS SEAT

(see Fig.35).

Fig.25

Fig.32

Fig.33

Fig.34

Fig.35

MAN-052

10

- DETACH THE DIAPHRAGM FROM THE

EXHAUST VALVE BODY PULLING IT

BY HAND

(see Fig.36).

- DISASSEMBLE THE SPRING RING

RETAINING THE DIAPHRAGM AND

VALVE PISTON, ALSO CALLED " “HEAD"

AND REMOVE IT.

(see Fig.37).

- CLEANCAREFULLY THE VALVE PARTS

AND REMOVE THE EXHAUST GAS AND OIL

RESIDUES

(see Fig.38).

ATTENTION

DO NOT USE AN AGGRESSIVE

DEGREASERTO AVOID DAMAGING THE

RUBBER PARTS

13. REMOVE CYLINDER HEAD

- UNSCREW N°5 M8 NUTSBY HALF TURN

(CROSS PATTERN DISASSEMBLY) AND

REMOVE THEM

(see Fig.39).

(ALLEN T TYPE - 13mm SOCKET

WRENCH).

- REMOVE THE WASHERS.

Fig.39

Fig.36

Fig.37

Fig.38

MAN-052

11

14. REMOVE CYLINDER

- UNSCREW N°4 NUTS M8 BY HALF TURN

(CROSS PATTERN DISASSEMBLY ) AND

REMOVE THEM

(see Fig.40).

(12mm SOCKET WRENCH)

- REMOVE WASHERS.

- REMOVE CYLINDER BASE GASKET

15. REMOVE PISTON

- REMOVE PISTON PIN CIRCLIPS FROM

PISTON

(see Fig.41).

(SCREWDRIVER WITH ROUNDED EDGE)

ATTENTION:

PAY ATTENTION NOT TO SCRATCH THE

PISTON AND CIRCLIPS SEAT.

- REMOVE PISTONPIN BY USING THE

SPECIAL PISTON PIN PUNCH TOOL

(P.N. 10200)

(see Fig.42).

- REMOVE PISTON

- REMOVE ROLLER CAGE

16. OPENING THE CRANKCASE

- UNSCREW N°9 SCREWS M6 (see Fig.43).

(5mm ALLEN WRENCH – T TYPE)

- OPEN THE CRANKCASEWITH THE HELP

OF A PLASTIC MALLET

(PREVENT THE CRANKSHAFT FROM

FALLING)

Fig.40

Fig.43

Fig.41

Fig.42

ATT.: screw on the

starter side

MAN-052

12

- REMOVE THE CRANKSHAFT

(See Fig.44).

- REMOVE OIL SEALS

(USE A SCREWDRIVER)

(see Fig.45).

17. REMOVE BEARINGS (IF NECESSARY)

MEASURE THE BEARINGS INTERNAL

DIAMETER IN DIFFERENT POINTS.

REFER TO THE ATTACHED TABLE TO

CHECK THE BEARING WEAR STATUS.

- REMOVE BEARINGS FROM CRANKSHAFT

WITH THE SPECIAL TOOL

(ATT.011/2) (see Fig.46).

- REMOVE THE BALANCE SHAFT OUTER

BEARING FROM THE SUPPORT

(see Fig.47).

Fig.46

Fig.47

Fig.44

Fig.31

Fig.45

1

MAN-052

13

- REMOVE THE BALANCE SHAFT INTERNAL

BEARING WITH THE SPECIAL TOOL AFTER

HAVING REMOVED THE OIL SEAL

(ATT.011/3) (see Fig.48).

2 – CRANKSHAFT DISASSEMBLY / ASSEMBLY

ATTENTION:

THE ASSEMBLY/DISASSE

MBLY OPERATIONS ON THE ENGINE CRANKSHAFT, MUST BE

PERFORMED ONLY BY AN AUTHORIZED SERVICE CENTER USING THE SPECIALLY DESIGNED

TOOLS. USE OF UNFITTED TOOLS OR OPERATIONS PERFORMED BY UNSKILLED PERSONNEL

MAY DAMAGE THE CRANKSHAFT BEYOND REPAIR.

TOOLS DESCRIPTION P.N.

CRANKSHAFT ASSEMBLY TOOL 10110B-C

CRANKPIN BUSH (INCLUDED IN 10110B-C) 10150A

CRANKSHAFT DISASSEMBLY TOOL KIT WITH : 10100A-C2

CRANKSHAFT SUPPORT 10100

CRANKSHAFT PLATE 10104A

CRANKSHAFT INSERT 10106

CRANKPIN PUSHER 10107

2.1 – CRANKSHAFT DISASSEMBLY

OPERATIONS PICTURES

1. PLACE THE DISASSEMBLY TOOL

(P.N. 10100A-C2) UNDER THE PRESS

(PRESS 5 MeT).

2. PLACE THE CRANSHAFT IN THE TOOL

BY INSERTING THE CRANKSHAFT PLATE

(P.N. 10104A) BETWEEN THE CRANKSHAFT

HALVES (see Fig.1).

Fig.1

Fig.48

MAN-052

14

3. PLACE THE CRANKSHAFT INSERT

(P.N. 10106) AND USING THE CRANKPIN

PUSHER ( P.N. 10107 ) PRESS THE

CRANKPIN OUT

(see Fig.2).

4. DISASSEMBLE THE COMPLETE CON-ROD

WITH WASHERSAND CAGE.

REPEAT THE OPERATIONS TO EXTRACT

THE CRANKPIN FROM THE OTHER HALF

CRANKSHAFT (see Fig.3).

INSERT A CRANKPIN ORBOARD ROLL IN

THE CAGE TO PREVENT THE ROLLERS

FROMFALLING.

BEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE

a) CHECK STATUS OF CON-ROD (TOP

AND BOTTOM).

IF OVALIZATION EXCEEDS 0.01mm,

REPLACE CON-ROD.

- 0.001 BORE GAUGE WITH CHECK RING Ø26 AND Ø19

b) CHECK STATUS OF CRANKPIN

(VISUAL CHECK) – REPLACE IF

NECESSARY

REPLACE AFTER 30 WORKING HRS.

c) CHECK STATUS OF CAGE (BIG END)

(VISUAL CHECK) – REPLACE IF

NECESSARY

REPLACE AFTER 30 WORKING HRS.

d) CHECK STATUS OF CRANKSHAFT

HALVES.

CHECK BEARING SEATS IN

DIFFERENT POINTS.

REFER TO THE ATTACHED TABLE TO

CHECK THE WEAR STATUS OF THE

CRANKSHAFT HALVES.

- CENTESIMAL MICROMETER 0÷25 o 25÷50

e) CHECK STATUS OF SILVER SHIMS

(VISUAL CHECK) – REPLACE IF

NECESSARY .

FOLLOW ATTACHED TABLE FOR MAX. MATCHING PLAY

Fig.2

Fig.3

MAN-052

15

2.2 – CRANKSAHFT ASSEMBLY

OPERATIONS PICTURES

1. PLACE THE CRANKSHAFT ASSEMBLY

TOOL (P.N. 10110B-C) UNDER THE PRESS,

VERTICALLY (PRESS 5 MeT).

2. PLACE THE CRANKSHAFT INTO THE

ASSEMBLY TOOL.

3. OIL CRANKPIN HOLE ON CRANKSHAFT

HALF.

4. PLACE CRANKPIN WITH CRANKPIN BUSH

(P.N. 10150A) ON CRANKSHAFT HALF

(see Fig.1).

5. BRING UPPER PLATE OF TOOL IN

CONTACT WITH CRANKPIN (see Fig.2).

6. PROGRESSIVELY PRESS UNTIL CRANKPIN

IS COMPLETELY DRIVEN IN

(see Fig.3).

Fig.1

Fig.2

Fig.3

MAN-052

16

7. EXTRACT CRANKPIN BUSH, OIL

CRANKPIN AND INSTALL:

-SILVER SHIM

-CON-ROD WITH ROLLER CAGE

-SILVER SHIM

(see Fig.4).

ATTENTION:

ROLLERS ARE FREE IN THE CAGE.

PREVENT THEM FROM FALLING,

WHEN INSERTING THE CAGE ON THE

CRANKPIN.

8. PLACE CLAMP JIG IN HORIZONTAL

POSITION AND PLACE HALF CRANKSHAFT

(see fig.5)

9. PLACE THE SECOND CRANKSHAFT IN

THE COUNTERPLATE SEAT

(see Fig 6)

10. BRING THE 2 PLATES CLOSE UNTIL THE

TOOL IS HAND PRESSED

(see Fig.7).

CHECK THAT CRANKPIN IS CORRECTLY

FITTED IN THE HOLE OF THE RECEIVING

CRANKSHAFT HALF.

Fig.4

Fig.5

Fig.6

Fig.7

MAN-052

17

11. OIL CRANKPIN AND CRANKPIN HOLE ON

HALF CRANKSHAFT.

12. PUT TOOL IN VERTICAL POSITION (see

Fig.8).

13. PROGRESSIVELY PRESS THE TWO

CRANKSHAFT HALVES TOGETHER.

14. OPEN THE TOOL, PUT IT IN HORIZONTAL

POSITION AND EXTRACT CRANKSHAFT.

15. CHECK THE AXIAL PLAY OF THE CON-ROD

(see Fig. 9).

IT MUST BE MIN. 0.4mm / MAX. 0.7mm.

IF PLAY IS HIGHER OR LOWER, REBUILD

THE CRANKSHAFT.

AFTER ASSEMBLING THE CRANKSHAFT, IT MUST BE ALIGNED, OTHERWISE EXCESSIVE

VIBRATIONS, HARD STARTING OR POOR ACCELERATION WILL RESULT.

a. PLACE THE CRANKSHAFT BETWEEN THE

CENTERS, WITH DIAL INDICATORS

READING ON FRONT AND REAR BEARING

JOURNALS

(see Fig.10).

(CENTERS WITH CENTESIMAL DIAL

GAUGES AND COPPER HAMMER FOR

ALIGNMENT).

Fig.8

Fig.9

Fig.10

MAN-052

18

b. ROTATE CRANKSHAFT AND CHECK

DEFLECTION OF GAUGE NEEDLES

THE DEFLECTION MUST BE, AFTER

CENTERING, MAX. 0.01mm

(see drawing).

c.

ADJUST ALIGNMENT WITH A COPPER

HAMMER, IF NECESSARY

(see Fig.11).

3 –REEDSTER 125cc ENGINE ASSEMBLY

BEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE

OPERATIONS PICTURES

1. INSTALLING BEARINGS

-INSERT EVENTUAL BEARING SHIMS IN

THE CRANKSHAFT BEARING SEATS (see Fig.

1) AND PLACE THE CRANKCASE HALVES

UNDER THE PRESS.

Fig.1

Fig.11

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IAME Parilla Reedster 125cc Overhauling Manual

IAME Parilla Reedster 125cc Overhauling Manual

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