IAME Parilla x30 125cc RL-TaG Assembly Instructions & User Manual
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IAME Parilla x30 125cc RL-TaG Assembly Instructions & User Manual

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ASSEMBLY INSTRUCTIONS

&
USER MANUAL
MAN-043/B
20/10/11

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Summary of Contents for IAME Parilla x30 125cc RL-TaG

  • Page 1: Assembly Instructions

    ASSEMBLY INSTRUCTIONS & USER MANUAL MAN-043/B 20/10/11...

  • Page 2: Table Of Contents

    I N D E X Page Section 1 DESCRIPTION OF THE “Parilla X30 125cc RL - TaG” ENGINE 1.1. Main features 1.2. Characterisstics of the Engine / Operational limits 1.3. Contents of packing 1.4. Accessories 1.5. Motor identification number Section 2 PREPARATION &...

  • Page 3: Section 1 Description Of The "Parilla X30 125Cc Rl - Tag" Engine

    Section 1 - DESCRIPTION OF THE “Parilla X30 125cc RL - TaG” ENGINE 1.1 MAIN FEATURES The “Parilla X30” has been expressly designed and tuned for powering the karts for hobby racing on closed tracks destined for this specific purpose. When designing this new engine, we have considered the technical solutions already adopted for the high performance engines, and the experience acquired with the TaG engines (Touch and Go).
  • Page 4 • Max. RPM: 14.000,15.500 and 16.000 (with rev. limiter) depending on the versions • Min. water temperature: 45°C • Temperatura max. acqua: 65°C ATTENTION: Never exceed the above limits; no obligation of IAME exists in case the above limits are exceeded. MAN-043/B...
  • Page 5 1.3 CONTENTS OF THE PACKING Each “Parilla X30” engine is supplied with the accessories under shown: EXHAUST SYSTEM QUANTITY • Flexible • Spring for flexible • Exhaust fiber strip • Exhaust manifold • Exhaust muffler INDUCTION • TRYTON HOBBY 27-C carburettor – Ø26 •...

  • Page 6: Accessories

    1.4 ACCESSORIES NGK SPARK PLUG EXHAUST SYSTEM BATTERY WITH SUPPORT STARTER BRUSHES KIT CLUTCH COVER / H.T. COIL COMPLETE ELECTRIC ASSEMBLY THERMOSTAT TRYTON HOBBY CARBURETOR RADIATOR SUPPORT KIT INTAKE SILENCER COMPLETE PUMP ASSEMBLY WATER HOSE KIT RADIATOR MAN-043/B...

  • Page 7: Motor Identification Number

    NOTE: In case of need for spares and when contacting the IAME Support Centers, please always refer to the Motor Identification Number and to the motor model. MAN-043/B...

  • Page 8: Section 2 Preparation & Installation Of The Engine On The Chassis

    Section 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 3.

  • Page 9: Install The Water-Cooling System

    2.2 INSTALL THE WATER COOLING SYSTEM NOTE: To install the water pump belts it is necessary to remove the rear axle. REINSTALL THE REAR AXLE AFTER Fig.1 HAVING INSERTED TWO BELTS. SUGGESTION: INSTALL OTHER TWO BELTS AS SPARES AND FIX THEM WITH TAPE TO THE AXLE. INSTALL THE WATER PUMP (1 SCREW M8x45 WITH WASHER AND NUT) ON THE PUMP BRACKET ON THE REAR CROSS...
  • Page 10 INSTALL THE BELTS AND TENSION (SEE FIG. 4). TIGHTEN THE SCREW M8x45. TORQUE AT 18÷22 Nm (160 ÷190 in-lb) Fig.4 BEFORE INSTALLING THE RADIATOR PREASSEMBLE THE FOLLOWING COMPONENTS INSERT THE 4 RUBBER DAMPENERS INTO THE FIXING HOLES ON THE RADIATOR (SEE FIG.
  • Page 11 - COMPLETE INSERTION OF THE RADIATOR SUPPORT BRACKET IN THE RUBBER DAMPENERS (SEE FIG. 7 AND 8). Fig.7 Fig.8 FIX THE RADIATOR SUPPORT BRACKET INSERTING ALSO THE RADIATOR FIXING BRACKET (RADIATOR CAP SIDE – N°1 SCREW M6x90 AND N°1 SCREW M6x85 RADIATOR FIX.
  • Page 12 PLACE THE RADIATOR FIXING CLAMP ON THE CHASSIS SIDE RAIL (BRAKE SIDE) (N°2 SCREWS M6x25). TIGHTEN THE BOLTS BY HAND (SEE FIG. 10). PLACE THE RADIATOR SO THAT THE HOLE ON THE RADIATOR BRACKET AND ONE OF THE UPPER HOLES ON THE BEARING SUPPORT BOX , MATCH (N°1 SCREW M8) ONCE YOU FIND THE CORRECT POSITION TIGHTEN THE M6x25 SCREWS ON THE...

  • Page 13: Exhaust Header Assembly

    Fig.1 EXHAUST HEADER ASSEMBLY NOTE: ENGINE SUPPLIED WITH EXHAUST GASKET AND NUTS ALREADY INSERTED. WHEN THE SHIPMENT IS MADE THE INTERNAL PARTS OF THE ENGINE ARE PROTECTED BY A BLIND GASKET. (SEE FIG. 2.3.1 REMOVE THE NUTS AND THE EXHAUST COVER.

  • Page 14: Install The Carburetor

    6 mm ALLEN WRENCH 2.4.2 INSTALL THE MOTOR-MOUNT, MAKE SURE TO USE THE M8 ALLEN SCREWS, WITH A LENGHT SUCH AS TO ENGAGE, IN THE CRANKCASE, A THREADED LENGHT OF 16÷19mm (THE SCREW MUST PROTRUDE FROM THE PLATE FOR 16÷19mm ) (SEE FIG. 3 AND DRAW.

  • Page 15: Install The Engine On The Chassis

    INSTALL THE ENGINE ON THE CHASSIS 2.6.1 POSITION THE ENGINE ON THE TWO OUTSIDE MAIN RAILS AND FIX THE MOTOR- MOUNT WITH TWO CLAMPS (SEE FIG. 6) SUGGESTION: NEVER TORQUE COMPLETELY THE CLAMPS UNTIL CHAIN INSTALLED PROPERLY ALIGNED. Fig.6 2.6.2 CHECK THE ALIGNMENT OF THE ENGINE SPROCKET...

  • Page 16: Install The Clutch Cover With H.t. Coil

    INSTALL THE CLUTCH COVER WITH 5 mm ALLEN H.T. COIL Fig.10 2.7.1 REMOVE THE 3 SCREWS M6x25 ON THE CRANKCASE (SEE FIG.10) AND INSTALL THE CLUTCH COVER WITH H.T. COIL. (SEE FIG.11). TORQUE THE 3 SCREWS AT 8 ÷ 10 Nm (70÷ 90 in-lb).
  • Page 17 Fig.13 ELECTRICAL CONNECTIONS (Refer to the attached electrical schematic). NOTE: For a correct installation follow the under shown instructions. 2.8.1 INSERT THE BATTERY STRAP IN THE BATTERY SUPPORT (SEE FIG. 13). 10mm BOX WRENCH 2.8.2 PLACE THE BATTERY SUPPORT BOX Fig.14 IN THE FRONT OF THE CHASSIS (UNDER THE FRONT FAIRING) AND FIX IT WITH THE...
  • Page 18 2.8.5 –CONNECT THE TERMINAL FROM THE Fig.17 IGNITION WITH THE 8 POLE TERMINAL ON THE HARNESS SEE FIG. 17). -CONNECT THE ONE WAY TERMINAL FROM THE ELECTRIC STARTER WITH THE ONE WAY TERMINAL ON THE HARNESS (SEE FIG. 18). ATTENTION: MAKE SURE THAT THE FIXING TONGUES PROPERLY INSERTED...
  • Page 19 5 mm ALLEN 2.8.8 FIX THE GROUND CABLE TO THE Fig.21 ELECTRIC STARTER BY MEANS OF THE M6x12 SCREW (ALREADY ON THE ENGINE SEE FIG. 21). TORQUE AT 8 ÷ 10 Nm (70 ÷90 in-lb) ATTENTION: THIS OPERATION EXTREMELY IMPORTANT UNCERTAIN GROUNDING COULD...
  • Page 20 2.8.11 CUT THE DUAL-LOCK FIXING STRAP AND ATTACH IT TO THE ELECTRONIC BOX, THE STARTER FUSE, AND THE FUSE HOLDER (SEE FIG.25). RELAY FUSE HOLDER Fig.25 ELECTRONIC BOX. 2.8.12 CONNECT THE ELECTRONIC BOX TO THE 20 POLE TERMINAL IN THE WIRING HARNESS (SEE FIG.
  • Page 21 Fig.29 2.8.14 CONNECT THE CABLE FROM THE STARTING ASSEMBLY WITH THE 8 POLE TERMINAL IN THE WIRING HARNESS (SEE FIG. 29). ATTENTION: MAKE SURE THAT THE FIXING TONGUES PROPERLY INSERTED GUARANTEE BEST POSSIBLE CONNECTION OF THE TERMINALS . 2.8.15 ATTACH THE DUAL LOCK FIXING Fig.30 STRAP (CLOSE TO THE STEERING COLUMN) AND PLACE THE ELECTRONIC...

  • Page 22: Install The Intake Silencer

    2.8.18 PLACE WIRING HARNESS BATTERY TERMINALS UNDER BATTERY STRP (SEE FIG. 33). SUGGESTION: NEVER CONNECT THE BATTERY UNTIL YOU ARE READY TO START THE ENGINE. SEAL THE BATTERY TERMINALS WITH PLASTIC TAPE TO AVOID THAT EVENTUAL VIBRATIONS MIGHT DISCONNECT TERMINALS. Fig.33 2.8.19 SCREW THE SPARK CAP ON THE Fig.34...

  • Page 23: Install The Exhaust

    2.10 INSTALL THE EXHAUST NOTE: SEE SECTION 3.8 FOR THE RECOMMENDATIONS ON THE IDEAL EXHAUST LENGHT. 2.10.1 INSTALL THE FLEXIBLE (L= 65mm Fig.37 FLEXIBLE COMPLETELY CLOSED –) AND THE EXHAUST HEADER (SEE FIG. 37) AND FIT THE INSULATING SLEEVE ON THE FLEXIBLE FLEXIBLE (SEE FIG.

  • Page 24: Charging Of The Oil In The Gear Box

    Section 3 - USE OF THE ENGINE 3.1 CHARGING OF THE OIL IN THE GEARBOX ATTENTION: The engine is suplied without oil in the gear box. Before starting the engine fill the box with SAE 30 oil. Starting the engine with a dry box will damage the gears beyond repair - Charge of the gear box: Put the engine in horizontal position, unscrew the oil plug (n°1 on the picture), and oil level...

  • Page 25: Carburetor Adjustment Guide

    3.3 CARBURETOR ADJUSTMENT GUIDE ( L ) LOW SPEED FUEL MIXTURE ( H ) HIGH SPEED FUEL MIXTURE ( I ) THROTTLE SPEED SCREW 1 T.O. RICH LEAN ¼ ¾ T.O. T.O. ½ T.O. T.O. = TURNS OPEN Normally the correct setting of the mixture screws, after engine run-in, is the following: L (close the screw completely and then open): 1 T.O.

  • Page 26: Starting And Stopping The Engine

    3.4 STARTING AND STOPPING THE ENGINE Starting is achieved by the starting key. This is a 3 position key: 1- STOP (key can be removed) 2- KEY 3- RUN In STOP position the battery is disconnected and the engine stop signal is sent to the electronic box.

  • Page 27: Engine Break-In

    3.5 ENGINE BREAK-IN The break-in of the engine must be performed following a few fundamental rules: 1. Adjust the carburetion. Start with an adjustment on the rich side. 2. Warm the engine gradually for about 5 minutes at half throttle, making some laps at low speed, gently closing and opening the carb.
  • Page 28 3.8 EXHAUST SYSTEM Before every test, make sure that the flexible is not damaged. Replace if necessary. ATTENTION: In case the flexible is damaged, metallic particles could be sucked in the engine and cause a seizure. Always make sure that the springs are well hooked and in place. In case of breakage, replace the broken spring.
  • Page 29 3.9 BATTERY The battery (12 V – 9 Ah) is sealed and without maintenance. In order to lenghten the battery life it is necessary though to follow a few recommendations: When the tension drops below 12.6V. It is necessary to recharge the battery. Max.

  • Page 30: Warnings On The Electrical System

    Only use 5A strip fuse. Use of fuses with higher amperage might damage the electronic box whenever the battery polarity is reversed. 12) Only use sealed lead type batteries as specified by IAME. Only use 12V. batteries. 13) Always disconnect the battery from the electrical system when recharging the battery with an external battery charger, otherwise the internal voltage regulator could be damaged.

  • Page 31: Spark Plug And Thermal Degree

    3.11 SPARK PLUG AND THERMAL DEGREE The engine is supplied with a standard NGK BR10EG 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 possible and, as a general information, we are attaching a correspondence list among spark plug of other brands, based on thermal degree which represents the capacity of the spark plug to dissipate the internal heat.
  • Page 32 According to the different engine versions. ATTENTION: Never exceed the above limit. No obligation of IAME exists in case the above limit is exceeded. 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 33 The following example should clarify the procedure for the optimization of the sprocket ratio. Assume to use the engine with Z=10 teeth engine sprocket and that during the preliminary track tests a Z= 77 teeth axle sprocket has been used. From Table 1 with Z=10 as engine sprocket and Z= 77 on the axle sprocket, a ratio of 7.70 is found.
  • Page 34 MAN-043/B...

  • Page 35: Centrifugal Clutch

    Section 4 - BASIC MAINTENANCE 4.1 CENTRIFUGAL CLUTCH The engine has a low maintenance dry centrifugal clutch. The following prescriptions, if carefully followed, will allow a long clutch life. When starting the engine, make sure that the brake pedal is fully pressed to avoid sudden accelerations.
  • Page 36 4.2 INSTRUCTIONS FOR THE DISASSEMBLY/ASSEMBLY OF THE CLUTCH ATTENTION: the following operations can be performed by a skilled mechanic, under the conditions 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 37: Gear Timing Schematic

    Before assembling the clutch, wash with diluent the shaft taper, the connecting hole on the clutch body, the clutch drum and the starter ring. Install clutch 1. Install the starter ring on the clutch body by matching 12 point wrench 10 mm the three holes and the dragging pin (3 screws M6).

  • Page 38: Replacement Of The Starter Brushes

    4.4 REPLACEMENT OF THE STARTER BRUSHES OPERATIONS PICTURES DISASSEMBLE THE STARTER - UNSCREW N°2 SCREWS M6x35 (see Fig.1). (5mm ALLEN WRENCH – T TYPE) Fig.1 Fig.2 - REMOVE STARTER (see Fig.2). NOTE: ON THE ENGINES MANUFACTURED AFTER SEPTEMBER ‘05, THE STARTER CAN BE REMOVED WITHOUT TAKING AWAY THE GEARS COVER BUT SIMPLY BY REMOVING THE COVER CLAMP (see drawing)
  • Page 39 OPENING THE STARTER Fig.3 Fig.1 REMOVE THE PLASTIC CLAMP AND UNSCREW THE SCREW M4 FIXING THE INPUT CABLE TO THE STARTER (see Fig.3) (PHILLIPS SCREWDRIVER) Fig.4 - UNSCREW 3 SCREWS M5 “C” (see Fig.4) (PHILLIPS SCREWDRIVER) MAN-043/B...
  • Page 40 - REMOVE DRUM FROM STARTER Fig.4 KEEPING ROTOR IN ITS SEAT (BE SURE TO HOLD THE ROTOR ON ITS TOOTHED SIDE TO PREVENT BRUSHES FROM FALLING OUT FROM THEIR SEAT) (see Fig.5) Fig.5 Fig.6 - REMOVE ROTOR FROM STARTER HEAD (see Fig.6) ATTENTION: WHEN EXTRACTING ROTOR, THE BRUSHES...
  • Page 41 - REMOVE SILICONE FROM BRUSHES WITH A SCREWDRIVER (see Fig.9). - REMOVE SPRINGS Fig.9 Fig.9 - MAKING PRESSURE EXTERNALLY ON THE TIN PLATE TERMINAL, REMOVE BRUSH. (see Fig.10). Fig.10 - INSTALL NEW BRUSH TERMINAL INSIDE (see Fig.11). - PLACE LITTLE RUBBER CAP ON THE TERMINAL Fig.11 - REINSTALL THE PLATE AND FIXE IT...
  • Page 42 Fig.13 REPLACEMENT OF THE BRUSH “B” - UNLOOSE THE SCREW M3 “G” (see Fig.13) - EXTRACT THE BRUSH - FIX THE NEW BRUSH WITH SCREW M3 (PHILLIPS SCREWDRIVER) CLOSING THE STARTER - INSERT THE NEW BRUSH SPRING "A" INTO ITS SEAT. - INSTALL THE BRUSH .
  • Page 43 - CHECK THAT O-RING "H" IS INSTALLED ON THE STARTER HEAD. - INSERT STARTER DRUM ON THE HEAD BEING CAREFUL TO PREVENT ROTOR FROM ROTATING AND TO PREVENT THE BRUSHES FROM FALLING OUT OF THEIR SEAT (see Fig. 17). Fig.17 - SCREW THE 3 SCREWS M5 (see Fig.18).

  • Page 44: Scheduled Maintenance

    4.5 SCHEDULED MAINTENANCE Following some simple maintenance standards will allow the engine to perform more reliably and have a longer life. SCHEDULE COMPONENTS ACTIONS AND COMMENTS Before using Exhaust flexible Check status Exhaust spring Check status Insulating sleeve Check status Silencer Check status and fixing Check wear...

  • Page 45: Troubleshooting

    4.6 TROUBLESHOOTING Below are some common faults, their probable causes and suggested remedy. FAULTS PROBABLE CAUSES REMEDY Starter will not crank when Bad connections on starter cables Check and tighten turning the key to RUN position Bad grounding Check connections and tighten Interruption on fuse Replace strip...

  • Page 46: Torque Value

    4.7 ENGINE PRESERVATION When engine is to remain unoperative for a long period it must be preserved as follow: Disconnect the battery and charge it periodically (see sect. 3.9). Disconnect carburetor and clean it. Seal with tape the engine inlet and exhaust. The external of the engine must be cleaned.
  • Page 47 MAN-043/B...

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