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Related Manuals for IAME REEDJET 100cc
Summary of Contents for IAME REEDJET 100cc
- Page 1 REEDJET 100cc OVERHAUL MANUAL MAN-086 - EN...
- Page 2 Overhaul MANUAL REEDJET 100 cc - INDEX ENGINE DISASSEMBLY CRANKSHAFT DISASSEMBLY/ ASSEMBLY CRANKSHAFT DISASSEMBLY OPERATIONS CRANKSHAFT ASSEMBLY OPERATIONS ENGINE ASSEMBLY ATTACHMENTS - FASTENER TORQUE VALUE - CROSS PATTERN LOCKING ORDER ON CRANKCASE - MAIN PRESCRIPTIONS - WEAR STATUS EVALUATION TABLE FOR BEARING AND CRANKSHAFT - LITTLE/BIG END CONROD BEARING CLEARANCE - OVERHAUL TOOLS LIST...
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Page 3: Engine Disassembly
ENGINE DISASSEMBLY Insert n°2 screws M8x60 on bottom of crankcase to position and fix motor on bench (TOOLS FOR VISE ON BENCH - FOR TOOL SEE ATTACHED DRAWING S725/1) Remove Spark Plug Unscrew with 20.8mm SOCKET WRENCH – T TYPE, extract the sparkplug from the engine. MAN –... - Page 4 Remove the Exhaust Manifold Unscrew n°2 Column Nuts M8, 12 POINT WRENCH 13MM, remove n°2 washers, the exhaust manifold and its gasket. Remove The Clutch Cover Unscrews n°3 M6x30 TCEI with 5mm ALLEN WRENCH – T TYPE. Remove The Clutch Unscrew the Bendix cover with 5mm ALLEN WRENCH –...
- Page 5 Remove the M10 Nut with RING WRENCH 17mm and remove subsequently the external washer, the complete drum with the roller cage, the internal washer and O-ring. With the starter wheel locking tool and SOCKET WRENCH 27mm, remove the M20x1clutch hub nut. WARNING: USCREW CLOCKWISE AS THE NUT HAS LEFT-HAND THREAD.
- Page 6 Remove The Ignition If you have to disassemble only the ignition, is possible remove only the Bendix cover on the clutch side as in photo. The important fact is that the ATT.037 STARTER WHEEL LOCKING TOOL is in place on the crankcase. Remove the ignition Nut M10 with the Ring Wrench 17mm.
- Page 7 Remove the Carburettor gasket, unscrews n°4 TCEI M6x25 with ALLEN WRENCH 5mm T TYPE. Remove the other components of inlet system as in picture. Remove the Cylinder Head Unscrew Head Nuts, n°2 Nuts M8 and n°2 Column nuts with SOCKET WRENCH 13MM T-TYPE Remove Cylinder O-Ring Ø60mm , remove cable spring, remove Cylinder and its gasket.
- Page 8 Remove the Circlips from Piston Use a Screwdriver with rounded edges. ATTENTION: DO NOT SCRATCH PISTON OR CIRCLIP SEATS. Remove Piston Pin, Piston and Cage Using the PISTON PIN PUNCH - P.N.10200 Remove Starter Group Untighten the screws that fix the starter support to the engine. Remove also the screws that attach the Bendix support to the engine.
- Page 9 Opening The Crankcase Remove 7 fixing Screws (n°5 M6x45 n°3 M6x60), unscrew with ALLEN WRENCH 5mm. Open the crankcase using a PLASTIC MALLET. Remove Oil Seals / Bearing if necessary Use a SCREWDRIVER for Seals. For the bearing, heat crankcase half to 70° or use press and special pusher as in picture S725/1.
- Page 10 USE OF UNFITTED TOOLS OR PERFORMED OPERATIONS BY UNSKILLED PERSONNEL MAY DAMAGE THE CRANKSHAFT BEYOND REPAIR. N° PART TOOLS DESCRIPTION CRANKSHAFT ASSEMBLY KIT 10110A CRANKPIN BUSH ( INCLUDED IN 10110A) 10150A CRANKSHAFT DISASSEMBLY KIT INCLUDES 10100-C2 - CRANKSHAFT SUPPORT/ DISASSEMBLY TOOL 10100 - CRANKSHAFT PLATE / DISASSEMBLY TOOL 10104A...
- Page 11 BE SURE THAT CRANKPIN IS WELL CENTERED INTO ITS HOLE ON CRANKSHAFT. Bring upper plate of tool in contact with crankpin. Progressively press until crankpin is completely driven in. Now extract bush from crankpin and put in horizontal position. After having lubricated crankpin, insert the silver washer, the conrod with roller cage and the other silver washer.
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Page 12: Engine Assembly
Oil crankpin and crankpin hole on crankshaft half. Put tool in vertical position. Progressively press the two crankshaft halves together. Open the tool, put it in horizontal position and extract the crankshaft. Check the axial clearance of the conrod, it must be MIN. 0.4mm / MAX. 0.6mm IF CLEARANCE IS HIGHER OR LOWER, REBUILD THE CRANKSHAFT AFTER ASSEMBLY, THE CRANKSHAFT MUST BE ALIGNED. - Page 13 Check status of crankcase bearing, replace after 30 hours suggested or 60 hrs max. Place crankcase halves under press (use tool as per drawing S 725 / 1). Or better heat crankcase half at 70°C. If necessary insert the bearing shims. Insert the bearing, the balls have to be on upper side and visible during the assembly (for both halves).
- Page 14 Once the correct clearance is achieved, disassemble the crankcase cleaning the surface with diluent and apply liquid gasket (Motorseal or equivalent) on one side of crankcase half. Be careful to clean eventual excess of product. Lubricate crankshaft seat before insertion, prevent oil from falling onto liquid gasket.
- Page 15 ATTENTION: THE OIL SEAL SHOULD BE REPLACED AFTER MAX 10 HOURS AND ALWAYS WHEN DISASSEMBLED Install Piston Check status of roller cage, the cage must be replaced after use of 160 litres or 20 hours. Check status of piston pin, must be replaced when replacing piston or 10÷20 hours. SEE ATTACHMENT ON MATCHING SELECTIONS ATTENTION FIRST CHECK THE PISTON RING END GAP USING A THICKNESS GAUGE.
- Page 16 Lubricate any components. Make sure that the arrow on top of the piston is towards the exhaust. As a general rule, the pin must be inserted in the hole with a little force. If tolerance is slack, replace it with a higher diameter pin. Using piston pin punch as guide. Position Circlip On Tool Grease tool to keep circlip in place, use TOOL P.N.
- Page 17 After the check, install O-Ring and cylinder head. Install n°4 head washer, then tighten n°2 Nuts M8 and n°2 Column nuts M8 with SOCKET WRENCH 13mm T-TYPE (18÷22Nm – 160÷190lb-in). Re-Assembly of The Clutch Before assembling the clutch, wash with the diluent: the shaft cone, the starter wheel and the clutch drum.
- Page 18 Apply the “Loctite” thread locker. Assemble fixing nut, clutch hub and starter wheel, using the STARTER WHEEL LOCKING TOOL and SOCKET WRENCH 27mm (torque 100÷110Nm 900÷990lb-in). WARNING: SCREW COUNTER CLOCKWISE AS THE NUT HAS LEFT-HAND THREAD. Assemble the internal washer (the bevel of the washer hole must be towards the shaft). Install the O-Ring.
- Page 19 Installation of Bendix Support Fit n°4 Screw M6x45 use 5mm ALLEN WRENCH – T TYPE (torque at 8÷10 Nm – 70÷90 lb-in). Grease the Bendix cage, insert the Bendix and fit the cover, n°3 M6x25 with 5mm ALLEN WRENCH – T TYPE (torque at 6÷8 Nm – 55÷70 lb-in). Installation of the Starter Support Place the support on the crankcase and tighten the n°3 M6x25 and n°1 M6x30, use 5mm ALLEN WRENCH –...
- Page 20 Re-Assemble The Ignition Install ignition rotor on shaft, the spacer-washer , the knurled washer and the nut M10. Remove the Bendix cover if was installed. Tighten all with a 12 POINT WRENCH 17mm and ATT.037 STARTER WHEEL LOCKING TOOL in position. Then remove ATT.037 STARTER WHEEL LOCKING TOOL, and install the Bendix cover.
- Page 21 Ignition Timing Install dial gauge with adapter on head, rotate rotor until piston is at T.D.C. put dial gauge at zero. Looking at the ignition, turn rotor clockwise 2.1mm, fix rotor to avoid it from turning. Rotate the stator until the two marks (on rotor and stator) match. Fix stator with n°2 screw TCEI M5x25 with 4mm ALLEN WRENCH –...
- Page 22 Position the reed pack and its gasket, install the reed pack group into the inlet seat of the engine, with IAME marking on top, check before tightening. Tighten n°4 TCEI M6x25 with ALLEN WRENCH 5mm T TYPE. Install the carburettor gasket.
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Page 23: Cross Pattern Locking Order On Crankcase
FASTENER TORQUE VALUE NOMINAL SIZE Q.TY FASTENER NAME WRENCH VALUES (Nm) VALUES (lb-in) M14x1,25 Spark Plug Hex.20,8 20 ÷ 26 175 ÷ 230 M8x1,25 Head and Cylinder Nuts Hex.13 18 ÷ 22 160 ÷ 190 M8x1,25 Exhaust manifold Stud Nuts Hex.13 18 ÷... - Page 24 ENGINE CRANKSHAFT MATCHING THE PISTON Bearing seat diameter on new engine ATTENTION: Clearance between piston and liner must be: Refer to the attached table to define the state of wear 0.090 / 0.095mm. of the drive shafts. The replacement operation must be carried out when If clearance is higher than 0.14mm, the piston size is lower than 0.03mm vs.
- Page 25 BEARINGS AND HALF CRANKSHAFT NOTE: ALWAYS CHECK DIMENSIONS IN DIFFERENT POINTS ON THE CIRCUMFERENCE, LOOKING FOR EVENTUAL OVALIZATIONS. The following chart shows the ovalization limits over which replacement is required Replace after Hours for MEASURED PART LIMITS Using (MEASURING INSTRUMENT) DEPENDING ON CRANKSHAFT –...
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Page 26: Overhaul Tool List
OVERHAUL TOOL LIST MAN – 086 – ENG - 25... - Page 27 SPECIFIC TOOLS AVAILABLE AT IAME DESCRIPTION P.N. • 10271 PISTON STROKE LOCKER • ATT.026 CLUTCH PULLER • PISTON PIN PUNCH 10200 • 10120 PISTON CIRCLIP ASSEMBLY TOOL • 10110-A CRANKSHAFT ASSEMBLY KIT it includes: - crankpin bush 10150A • KIT CRANKSHAFT DISASSEMBLY KIT 10100 –...
- Page 28 MATERIAL: Steel Fe 50 UNI 5332 Drawing S725/1 MAN – 086 – ENG - 27...
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Page 29: Wiring Diagram
WIRING DIAGRAM MAN – 086 – ENG - 28... - Page 30 MAN – 086 – ENG - 29...
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