IAME Parilla Reedster 125cc Overhauling Manual
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IAME Parilla Reedster 125cc Overhauling Manual

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See also: Assembly Instructions and User's Manual
REEDSTER 125cc
versions: F1 - F2 - F3 - F4
OVERHAULING MANUAL
07/11/07
1
MAN-052
21/01/2009

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  • Page 1 REEDSTER 125cc versions: F1 - F2 - F3 - F4 OVERHAULING MANUAL 07/11/07 MAN-052 21/01/2009...
  • Page 2 INDEX Page 1. - REEDSTER 125cc ENGINE DISASSEMBLY 2. - CRANKSHAFT DISASSEMBLY / ASSEMBLY 2.1 - CRANKSHAFT DISASSEMBLY 2.2 - CRANKSHAFT ASSEMBLY 3. - REEDSTER 125cc ENGINE ASSEMBLY ATTACHMENTS - FASTENER TORQUE TABLE - CROSS PATTERN LOCKING ORDER ON CRANKCASE - MAIN PRESCRIPTIONS - CONROD BIG END AND SMALL ENDS TOLERANCES - OVERHAULING TOOL LIST...
  • Page 3 1 –REEDSTER 125cc ENGINE DISASSEMBLY OPERATIONS PICTURES DISCHARGING OIL FROM GEARBOX Fig.1 - UNSCREW THE M6 SCREW FOR DISCHARGING OIL (see Fig.1). (5mm ALLEN WRENCH – T TYPE) Fig.2 - TILT THE ENGINE TO FACILITATE OIL DISCHARGING AND CHECK THAT THE GEARBOX BREATHER IS FREE AND (see Fig.2).
  • Page 4 REMOVE THE IGNITION Fig.4 - REMOVE STATOR UNSCREW N°3 M5x25 SCREWS (see Fig.4) (4mm ALLEN WRENCH – T TYPE) - REMOVE SPARKPLUG AND INSTALL THE Fig.5 SPECIAL PISTON RETAINER (P.N. 10271) TO LOCK THE CRANKSHAFT (see Fig.5). - REMOVE NUT M12 (see Fig.6). Fig.6 (17mm SOCKET WRENCH) - EXTRACT ROTOR WITH THE SPECIAL...
  • Page 5 DISASSEMBLE GEAR COVER Fig.8 M6x20 M6x30 - UNLOOSE N°2 SCREWS M6 FIXING THE STARTER CLAMP. - UNSCREW N°7 ALLEN HEAD SCREWS M6 M6x20 (see Fig.8). (5mm ALLEN WRENCH – T TYPE) M6x20 M6x30 - REMOVE COVER AND WASHER (see Fig.9). (WITH THE HELP OF A PLASTIC MALLET IF NECESSARY) ATTENTION:...
  • Page 6 REMOVE CLUTCH Fig.12 - DISASSEMBLE THE CLUTH COVER UNSCREW N°3 SCREWS M6x25 (see Fig.12). (5mm ALLEN WRENCH – T TYPE) - DISCONNECT THE GROUND CABLE FROM Fig.13 CRANKCASE UNSCREW M6x12 SCREW (see Fig.13). (5mm ALLEN WRENCH – T TYPE) - REMOVE STARTER COUNTERSHAFT Fig.14 COVER UNSCREW N°3 SCREWS M6x25...
  • Page 7 - REMOVE THE M20 NUT FIXING THE CLUTCH BODY (see Fig.16). (30mm SOCKET WRENCH) ATTENTION: TURN CLOCKWISE AS NUT HAS LEFT THREAD Fig.16 - REMOVE THE CLUTCH BODY AND THE STARTING GEAR FROM THE CRANKSHAFT BY MEANS OF THE CLUTCH DISASSEMBLY TOOL (P.N.
  • Page 8 REMOVE WATER PUMP Fig.20 - REMOVE PUMP COVER UNSCREW N°4 SCREWS M6x20 (see Fig.20). (5mm ALLEN WRENCH – T TYPE) Fig.21 - REMOVE COVER AND WASHER (see Fig.21). - INSTALL THE GEAR LOCKING TOOL Fig.22 (P.N. ATT-008) (see Fig.22). Fig.23 - UNSCREW SCREW M5X20 AND REMOVE PUMP IMPELLER (see Fig.23).
  • Page 9 REMOVE GEARS - REMOVE THE RETAINER RING ON THE COUNTERSHAFT (see Fig.24). (PLIERS FOR RETAINER RING) - REMOVE GEAR ON THE COUNTERSHAFT (USE THE PULLER P.N. ATT-010 IF NECESSARY) - REMOVE CONE SAFETY WASHER Fig.24 - UNSCREW NUT ON THE CRANKSHAFT Fig.25 (see Fig.25).
  • Page 10 Fig.28 - EXTRACT THE BEARING SUPPORT BY PUSHING COUNTER CRANKSHAFT FROM THE SIDE OF THE WATER PUMP (see Fig.28). ATTENTION: PAY ATTENTION NOT TO DAMAGE THE OIL SEAL LIP Fig.29 REMOVE THE CARB INLET DUCT - UNSCREW N°4 SCREWS M6x25 (see Fig.29).
  • Page 11 Fig.25 - REMOVE VALVE COVER AND RETAINING SPRING (see Fig.32). Fig.32 - UNSCREW N° 2 SCREWS M6 (see Fig.33). (5mm ALLEN WRENCH – T TYPE) Fig.33 - EXTRACT THE VALVE FROM THE Fig.34 CYLINDER (vedi Fig.34). Fig.35 - UNSCREW COMPLETELY THE SLIDE BY HAND AND REMOVE IT FROM ITS SEAT (see Fig.35).
  • Page 12 - DETACH THE DIAPHRAGM FROM THE Fig.36 EXHAUST VALVE BODY PULLING IT BY HAND (see Fig.36). Fig.37 - DISASSEMBLE THE SPRING RING RETAINING THE DIAPHRAGM AND VALVE PISTON, ALSO CALLED " “HEAD" AND REMOVE IT. (see Fig.37). Fig.38 - CLEAN CAREFULLY THE VALVE PARTS AND REMOVE THE EXHAUST GAS AND OIL RESIDUES (see Fig.38).
  • Page 13 Fig.40 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 REMOVE PISTON Fig.41 - REMOVE PISTON PIN CIRCLIPS FROM PISTON (see Fig.41).
  • Page 14 Fig.44 - REMOVE THE CRANKSHAFT (See Fig.44). - REMOVE OIL SEALS Fig.45 (USE A SCREWDRIVER) (see Fig.45). Fig.31 REMOVE BEARINGS (IF NECESSARY) Fig.46 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).
  • Page 15 - REMOVE THE BALANCE SHAFT INTERNAL Fig.48 BEARING WITH THE SPECIAL TOOL AFTER HAVING REMOVED THE OIL SEAL (ATT.011/3) (see Fig.48). 2 – CRANKSHAFT DISASSEMBLY / ASSEMBLY ATTENTION: THE ASSEMBLY/DISASSEMBLY OPERATIONS ON THE ENGINE CRANKSHAFT, MUST BE PERFORMED ONLY BY AN AUTHORIZED SERVICE CENTER USING THE SPECIALLY DESIGNED TOOLS.
  • Page 16 PLACE THE CRANKSHAFT INSERT (P.N. 10106) AND USING THE CRANKPIN PUSHER ( P.N. 10107 ) PRESS THE CRANKPIN OUT (see Fig.2). Fig.2 DISASSEMBLE THE COMPLETE CON-ROD WITH WASHERS AND CAGE. REPEAT THE OPERATIONS TO EXTRACT THE CRANKPIN FROM THE OTHER HALF CRANKSHAFT (see Fig.3).
  • Page 17 2.2 – CRANKSAHFT ASSEMBLY OPERATIONS PICTURES PLACE THE CRANKSHAFT ASSEMBLY TOOL (P.N. 10110B-C) UNDER THE PRESS, VERTICALLY (PRESS 5 MeT). PLACE THE CRANKSHAFT INTO THE ASSEMBLY TOOL. OIL CRANKPIN HOLE ON CRANKSHAFT HALF. PLACE CRANKPIN WITH CRANKPIN BUSH (P.N. 10150A) ON CRANKSHAFT HALF (see Fig.1).
  • Page 18 Fig.4 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. PLACE CLAMP JIG IN HORIZONTAL POSITION AND PLACE HALF CRANKSHAFT (see fig.5) Fig.5...
  • Page 19 OIL CRANKPIN AND CRANKPIN HOLE ON HALF CRANKSHAFT. Fig.8 PUT TOOL IN VERTICAL POSITION (see Fig.8). PROGRESSIVELY PRESS THE TWO CRANKSHAFT HALVES TOGETHER. OPEN THE TOOL, PUT IT IN HORIZONTAL POSITION AND EXTRACT CRANKSHAFT. Fig.9 CHECK THE AXIAL PLAY OF THE CON-ROD (see Fig.
  • Page 20 ROTATE CRANKSHAFT AND CHECK DEFLECTION OF GAUGE NEEDLES THE DEFLECTION MUST BE, AFTER CENTERING, MAX. 0.01mm (see drawing). Fig.11 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 INSTALLING BEARINGS...
  • Page 21 - INSERT CRANKSHAFT BEARINGS; BALLS Fig.2 TO BE VISIBLE ON UPPER SIDE DURING ASSEMBLY (see Fig. 2). - OIL OUTSIDE OF BEARINGS AND BEARING SEATS , BEFORE ASSEMBLY. USE SPECIAL TOOL (ATT-011/1) TO INSERT Fig.3 THE BEARINGS (see fig. 3) INSTALL THE INNER BALANCE SHAFT Fig.4 BEARING, BALLS TO BE ON UPPER SIDE...
  • Page 22 Fig.6 CRANKCASE ASSEMBLY - LUBRICATE THE CRANKSHAFT SEATS, BALL BEARINGS, BIG END CAGE BEFORE ASSEMBLING (vedi Fig.6). - ALSO LUBRICATE THE INNER BALANCE SHAFT BEARING. Fig.7 - INSTALL CRANKSHAFT THE CRANKSHAFT MUST BE IN SAME POSITION AS IN ORIGINAL INSTALLATION (see Fig.7).
  • Page 23 - INSERT CRANKSHAFT AND CLOSE Fig.10 CRANKCASE HALVES (see Fig.10). - ASSEMBLE CRANKCASE HALVES Fig.11 N°9 SCREWS M6 (see Fig.11). (CROSS PATTERN LOCKING – (SEE ATTAC HED SKETCH) TORQUE AT 8÷10 Nm (70 ÷ 90 lbf*in) (5mm ALLEN WRENCH – T TYPE) ATT.: screw starter side FITTING OIL SEALS...
  • Page 24 - ASSEMBLE BEARING SUPPORT AND Fig.14 BALANCE SHAFT M6x60 (see Fig.14). N°6 SCREWS M6 TORQUE AT 8÷10 Nm (70÷90 lbf*in) M6x20 M6x60 (5mm ALLEN WRENCH – T TYPE) LUBRICATE THE BALANCE SHAFT M6x60 EXTERNAL BEARING M6x60 M6x20 - INSTALL WATER PUMP SEAL WITH THE SPECIAL TOOL (P.N.
  • Page 25 NOTE: IF GEARS HAVE NOT BEEN REPLACED, REINSTALL THEM IN THEIR ORIGINAL Fig.18 POSITION . ( IDENTIFY THE GEAR MARKED DURING THE DISASSEMBLING AND ASSEMBLE IT ON CRANKSHAFT). INSTALL RETAINING RING ON THE BALANCE SHAFT MAKE SURE THAT RING IS IN PLACE AT BOTTOM OF ITS SLOT (see Fig.18).
  • Page 26 Fig.22 ASSEMBLING THE GEAR COVER - PLACE GASKET ON CRANKCASE (see Fig.21). - POSITION COVER BY INSERTING STARTER END IN ITS PROPER SEAT. (CHECK THAT THE VIBRATION DAMPING Fig.23 Fig.23 M6x20 M6x30 FITTING IS IN PLACE AND OIL IT BEFORE INSERTING THE STARTER).
  • Page 27 INSTALLING THE PISTON Fig.26 - CHECK STATUS OF THE PISTON PIN CAGE. IT IS RECOMMENDED TO REPLACE IT AFTER ALWAYS WHEN OVERHAULING THE ENGINE. - CHECK STATUS OF PISTON PIN. REPLACE IT WHEN REPLACING PISTON. SEE ATTACHMENT ON MATCHING SELECTIONS BETWEEN PISTON PIN / CAGE).
  • Page 28 - IINSERT CIRCLIPS Fig.30 (see Fig.30). CHECK CIRCLIPS TO BE IN SEAT. ATTENTION: THE CIRCLIP ENDS MUST BE OPPOSITE TO THE PISTON EXTRACTION NOTCH Fig.31 INSTALLING THE CYLINDER - PLACE A NEW GASKET ON THE CYLINDER BASE. OIL CYLINDER LINER AND PISTON. INSTALL CYLINDER (see Fig.31).
  • Page 29 Fig.34 ASSEMBLING THE IGNITION AND ENGINE TIMING - INSERT KEY ON SHAFT (see Fig.34). - INSTALL ROTOR ON SHAFT - INSTALL PISTON RETAINER (P.N. 10271) Fig.35 ON HEAD AND INSERT M12 NUT ON SHAFT. (see Fig.35). TORQUE AT 20÷26 Nm (175÷230 lbf*in) (17mm SOCKET WRENCH) Fig.36 - INSTALL STATOR...
  • Page 30 - AFTER HAVING SET TO "0" THE DIAL GAUGE Fig.38 ROTATE CRANKSHAFT IN THE OPPOSITE DIRECTION VS THE DIRECTION OF OPERATION (CLOCKWISE, LOOKING AT THE IGNITION): 2.3mm for F1 2.6mm forr F2 4.9mm for F3 4.1mm for F4 (see Fig.38). Fig.39 - PREVENTING THE CRANKSHAFT FROM TURNING, ROTATE IGNITION STATOR...
  • Page 31 BEFORE ASSEM BLING THE CLUTCH, WASH WITH DILUENT THE SHAFT TAPER, THE STARTER RING FIXING HOLE, THE CLUTCH BODY AND THE CLUTCH DRUM. INSTALLING THE CLUTCH - INSTALL STARTER RING ON CLUTCH BODY BY MATCHING THE 3 HOLES AND THE DRAGGING PIN (see Fig.42).
  • Page 32 Fig.46 - INSTALL CLUTCH DRUM, OUTER WASHER AND M10 NUT (see Fig.46). ATTENTION: INSTALL WASHER WITH BEVEL TOWARDS CRANKSHAFT - APPLY “LOCTITE 243” ON THREADS AND TIGHTEN THE M10 CLUTCH DRUM RETAINI NG NUT Fig.47 (see Fig.47). TORQUE AT 30÷40 Nm (265 ÷350 lbf*in) (17mm SOCKET WRENCH) - REMOVE THE STARTER RING LOCKING TOOL TOOL AND INSTALL THE...
  • Page 33 Fig.50 - INSTALL CLUTCH COVER N°3 M6x25 ALLEN SCREWS (see Fig.50). TORQUE AT 8÷10 Nm (80 ÷100 lbf*in) (5mm ALLEN WRENCH T TYPE) Fig.51 INSTAL THE REED GROUP - INSTALL INTERNAL GASKET, REED VALVE, EXTERNAL WASHER AND INLET DUCT, WITH PRESSURE AIR INTAKE HOLE TOWARDS UPPER SIDE (see Fig.51).
  • Page 34 Fig.54 - INSTALL HEAD ON THE DIAPHRAGM AND INSERT THE RETAINING SPRING WITH THE SPECIAL TOOL (see Fig.54). - INSTALL GASKET, SPACER AND O'RING, Fig.55 SLIDE SPINDLE AND SCREW IT IN THE "HEAD" UNTIL CONTACT BUT WITHOUT FORCING IT (see Fig.55). ATTENTION CHECK THAT THE GASKET PRESSURE HOLE MATCHES THE ONE ON THE VALVE...
  • Page 35 Fig.58 - FIX VALVE BODIES N°2 SCREWS M6 (see Fig.58). TORQUE AT 8÷10 Nm (70 ÷90 lbf*in) PROCEED AS FOLLOW:  SCREW IN THE M6 SCREWS WITHOUT TORQUING  CHECK THAT VALVE IS FREELY SLIPPING TORQUE SCREWS AT 4÷5 Nm (35 ÷45 lbf*in) ...
  • Page 36 COUPLES ON TIGHTENING OF NUTS AND SCREWS MAN-052...
  • Page 37 CROSS PATTERN LOCKING ORDER ON CRANKCASE MAN-052...
  • Page 38 MAIN PRESCRIPTIONS CRANKSHAFT MATCHING THE PISTON ATTENTION: - Bearing seat diameter on new engine Play between piston and liner must be 0.11÷0.12mm. For halfcrankshaft wear, please refer to the If play is higher than 0.14mm replace piston attached table. Piston to be measured at 18mm from the base. MAX ALLOWED OVALIZATION OF CON-ROD BIG-END The piston size is marked on the top with a green...
  • Page 39 MAN-052...
  • Page 40 OVERHAUL TOOL LIST SPECIFIC TOOLS AVAILABLE AT IAME DESCRIPTION P.N.  GEAR DISASSEMBLY TOOL ATT-010  ROTOR DISASSEMBLY TOOL ATT-009  PISTON FITTING 10271  CLUTCH DISASSEMBLY TOOL 10272-C  PISTON PIN FITTING TOOL 10200   CRANKSHAFT ASSEMBLY KIT...
  • Page 41 TABLE FOR WEAR EVALUATION ON BEARINGS/ HALFCRANKSHAFTS NOTE: ALWAYS CHECK DIMENSIONS IN DIFFERENT POINTS ON CIRCUMFERENCE, LOOKING FOR EVENTUAL OVALIZATIONS On the following Table are shown the ovalization limits above which replacement is required MEASURED PART LIMITS (MEASURING INSTRUMENT) CRANKSHAFT – BEARING SEAT (MICROMETER 0÷25 1/100) MIN.
  • Page 42 FIXING ENGINE TOOL ON BENCH VICE MAN-022...

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