IAME Parilla MINI SWIFT, Overhauling Manual

Page 1: ...12 10 05 MAN 045 ING 1 ENGINE OVERHAULING MANUAL 60cc BABY MINI SWIFT TaG ...

Page 2: ...SSEMBLY 7 2 1 CRANKSHAFT DISASSEMBLY 7 2 2 CRANKSHAFT ASSEMBLY 9 3 ENGINE ASSEMBLY 12 ATTACHMENTS FASTENER TORQUE VALUE CROSS PATTERN LOCKING ORDER ON CRANKCASE MAIN PRESCRIPTIONS LITTLE BIG END CONROD BEARING MATCHING PLAY OVERHAUL TOOLS LIST USE OF THE BATTERY CHARGER DRAWING S725 3 ...

Page 3: ...s per draw S725 3 2 REMOVE CLUTCH REMOVE CLUTCH COVER 3 SCREWS M6 See Fig 1 5mm ALLEN T TYPE REMOVE SPARKPLUG AND INSTALL SPECIAL PISTON FITTING SO THAT CRANKSHAFT DOES NOT ROTATE see Fig 2 PISTON FITTING P N 10271 REMOVE THE FIXING NUT M10 see Fig 3 REMOVE OUTER WASHER CLUTCH DRUM WITH ROLLER CAGE AND INNER WASHER 12 POINT WRENCH 17mm Fig 1 Fig 2 Fig 3 ...

Page 4: ...THREAD REMOVE SAFETY WASHER REMOVE CLUTCH FROM THE CRANKSHAFT USING THE CLUTCH DISASSEMBLY TOOL see Fig 5 CLUTCH DISASSEMBLY TOOL P N B 55614 C 12 POINT WRENCH 19mm REMOVE KEY FROM SHAFT SEAT REMOVE STARTER RING FROM CLUTCH 3 SCREWS M6 see Fig 6 12 POINT WRENCH 10mm 3 REMOVE THE IGNITION REMOVE THE IGNITION COVER 3 SCREWS M6X18 see Fig 7 4mm ALLEN T TYPE Fig 4 Fig 5 Fig 6 Fig 7 ...

Page 5: ...ISTON FITTING AND REMOVE NUT WITH WASHER PISTON FITTING P N 10271 12 POINT WRENCH 17mm REMOVE ROTOR see Fig 9 REMOVE KEY FROM CRANKSHAFT SEAT 5 REMOVE STARTER GROUP 4 SCREWS M6X45 see Fig 10 5mm ALLEN T TYPE REMOVE STARTER FROM SUPPORT 1 SCREW M6X16 1 SCREW M6X20 see Fig 11 12 Fig 10 Fig 11 Fig 8 Fig 9 ...

Page 6: ...RT COVER 3 SCREWS M6X20 see Fig 13 EXTRACT THE COUNTERSHAFT FROM THE SUPPORT see Fig 14 6 REMOVE THE HEAD LOOSEN NUTS BY TURN CROSS PATTERN DISASSEMBLY AND THEN REMOVE see Fig 15 4 NUTS M8 4 WASHERS 13mm SOCKET T TYPE Fig 13 Fig 14 Fig 12 Fig 15 ...

Page 7: ... SCREWDRIVER WITH ROUND EDGES ATTENTION DO NOT SCRATCH PISTON OR CIRCLIP SEATS 9 REMOVE PISTON PIN PISTON AND ROLLER CAGE USING THE PISTON PIN PUNCH see Fig 18 PISTON PIN PUNCH P N 10202 10 REMOVE THE FUEL PUMP DISCONNECT THE INTAKE PIPE FROM THE THE CRANKCASE FITTING see Fig 19 Fig 17 Fig 18 Fig 16 Fig 19 ...

Page 8: ...E 7 FIXING SCREWS see Fig 21 4 SCREWS M6X40 3 SCREWS M6X50 5mm ALLEN T TYPE PLASTIC MALLET OPEN THE CRANKCASE USING A PLASTIC MALLET AVOID CRANKSHAFT FROM FALLING REMOVE OIL SEALS USING A SCREWDRIVER see Fig 22 REMOVE BEARINGS IF NECESSARY HEAT HALFCRANKCASES AT 70 C see Fig 23 USE TOOL AS PER DRAW S725 3 REMOVE SHIMS Fig 21 Fig 22 Fig 23 Fig 20 ...

Page 9: ...0110 C CRANKPIN BUSH IN 10110 C 10150 CRANKSHAFT DISASSEMBLY KIT 10100 C3 CRANKSHAFT SUPPORT 10100 CRANKSHAFT PLATE 60cc 10103 CRANKSHAFT INSERT 60cc 10108 CRANKPIN PUSHER 10107 2 1 CRANKSHAFT DISASSEMBLY OPERATIONS TOOLS 1 PLACE THE DISASSEMBLY TOOL P N 10100 C3 UNDER THE PRESS 5 MeT PRESS CRANKSHAFT DISASSEMBLY KIT 2 PLACE THE CRANKSHAFT IN THE TOOL INSERTING THE CRANKSHAFT PLATE P N 10103 BETWE...

Page 10: ...IZATION EXCEEDS 0 01mm REPLACE CON ROD CENTESIMAL MICROMETER 21 50 BORE GAUGE WITH CHECK RING Ø24 and Ø16 b CHECK STATUS OF CRANKPIN VISUAL CHECK REPLACE IF NECESSARY BUT ALWAYS AFTER MAX 8 HRS WORKING c CHECK STATUS OF ROLLER CAGE BIG END VISUAL CHECK REPLACE IF NECESSARY BUT ALWAYS AFTER MAX 8 HRS WORKING d CHECK STATUS OF CRANKSHAFT HALVES REPLACE IF BEARING SEAT IS BELOW 0 03mm VS NEW FOLLOW A...

Page 11: ...HAFT ASSEMBLY KIT P N 10110 C 2 PLACE THE CRANKSHAFT HALF INTO THE ASSEMBLY TOOL 3 OIL CRANKPIN AND CRANKPIN HOLE ON CRANKSHAFT HALF 4 PLACE CRANKPIN WITH CRANKPIN BUSH P N 10150 ON CRANKSHAFT HALF see Fig 1 5 BRING UPPER PLATE OF TOOL IN CONTACT WITH CRANPKIN see Fig 2 6 PROGRESSIVELY PRESS UNTIL CRANKPIN IS COMPLETELY DRIVEN IN see Fig 3 Fig 1 Fig 2 Fig 3 ...

Page 12: ...CRANKPIN CONROD WITH ROLLER CAGE AND WASHERS see Fig 5 ATTENTION ROLLERS ARE FREE IN THE CAGE PREVENT ROLLERS FROM FALLING WHEN INSERTING ON CRANKPIN 9 PLACE SECOND CRANKSHAFT HALF IN THE SEAT OF THE COUNTERPLATE see Fig 6 10 BRING THE TWO PLATES CLOSE UNTIL THE TOOL IS HAND PRESSED see Fig 7 Fig 4 Fig 5 Fig 6 Fig 7 ...

Page 13: ...5 CHECK AXIAL PLAY OF THE CONROD see Fig 9 IT MUST BE MIN 0 3mm MAX 0 7mm IF PLAY IS HIGHER OR LOWER REBUILD THE CRANKSHAFT AFTER ASSEMBLING THE CRANKSHAFT IT MUST BE ALIGNED IF NOT EXCESSIVE VIBRATIONS HARD STARTING OR POOR ACCELERATION WILL RESULT a PLACE CRANKSHAFT BETWEEN THE CENTERS WITH DIAL INDICATORS READING ON FRONT AND REAR BEARING JOURNALS see Fig 10 CENTERS WITH CENTESIMAL DIAL GAUGES ...

Page 14: ...WITH COPPER HAMMER IF NECESSARY see Fig 11 3 ENGINE ASSEMBLING BEFORE REASSEMBLING WASH ALL THE PARTS WITH KEROSENE OPERATION TOOLS REQUIRED CRANKCASE REASSEMBLY a CHECK STATUS OF CRANKCASE BEARING VISUAL CHECK REPLACE AFTER 6 HRS MAX b PLACE CRANKCASE HALVES UNDER THE PRESS OR HEAT CRANKCASE HALF AT 70 C 1 c INSERT BEARING SHIMS see Fig 1 Fig 11 Fig 1 ...

Page 15: ...IAL TOOL AS PER DRAW S725 3 e INSERT CRANKSHAFT AFTER OILING CRANKSHAFT SEAT IN CRANKCASE CRANKSHAFT MUST BE IN SAME POSITION AS IN ORIGINAL INSTALLATION see Fig 4 f ASSEMBLE CRANKCASE HALVES n 4 SCREWS M6X40 n 3 SCREWS M6X50 see Fig 5 5mm ALLEN T TYPE CROSS PATTERN SEE DRAWING TORQUE AT 10 Nm MAX 90 in lb Fig 2 Fig 3 Fig 4 Fig 5 ...

Page 16: ... 0 15 0 20 TO RECOVER THE PLAY SHIMS MUST BE EQUALLY POSITIONED see Fig 6 BEFORE CLOSING DEFINITIVELY APPLY FLUID GASKET Motorseal or equivalent ON CRANKCASE HALVES AFTER CAREFULLY CLEANING THE SURFACE WITH DILUENT CLEAN EVENTUAL EXCESS OF PRODUCT see Fig 7 OIL CRANKSHAFT SEAT BEFORE ASSEMBLING see Fig 8 2 APPLY SPECIAL LUBRICANT ON OIL SEAL LIPS see Fig 9 SPECIAL TOOL AS PER DRAWING S725 3 Fig 6 ...

Page 17: ...ECK PLAY ON PISTON RING END GAPS TO BE BETWEEN 0 10 AND 0 15mm PLAY MUST BE CHECKED USING A THICKNESS GAUGE AND INSERTING THE PISTON RING IN THE CYLINDER see Fig 12 d INSTALL PISTON ATTENTION PLAY BETWEEN PISTON AND LINER MUST BE 0 08mm IF PLAY IS HIGHER THAN 0 10mm REPLACE PISTON FOLLOW ATTACHED INSTRUCTIONS FOR CORRECT MATCHING PISTONS ARE MEASURED AT 15mm FROM THE BOTTOM see attachment ALWAYS C...

Page 18: ...AT SPECIAL TOOL P N 10121 4 INSTALL A NEW CYLINDER GASKET 5 INSTALL CYLINDER see Fig 16 VISUAL CHECK OIL CYLINDER AND PISTON 6 CHECK STATUS OF CYLINDER HEAD CLEAN COMBUSTION CHAMBER FROM DEPOSITS DO NOT SCRATCH COMBUSTION CHAMBER 7 INSTALL HEAD 4 NUTS M8 WITH WASHERS CROSS TORQUE TORQUE AT 18 Nm 160 in lb 13mm SOCKET T TYPE Fig 14 Fig 15 Fig 16 ...

Page 19: ...TCH BODY BY MATCHING THE 3 HOLES AND THE DRAGGING PIN 3 SCREWS M6 TORQUE AT 10 Nm 90 in lb AND APPLY LOCTITE ON THREADS Loctite see Fig 17 18 ATTENTION MAKE SURE TO ALWAYS INSTALL THE Ø 7 DRAGGING PIN AS OTHERWISE THE KICKBACKS COULD BREAK THE SCREWS 10mm SOCKET T TYPE b INSERT THE KEY ON SHAFT see Fig 19 8 c INSTALL THE CLUTCH BODY AND THE CONE SAFETY WASHER see Fig 20 Fig 16 Fig 17 Fig 18 Fig 19...

Page 20: ...S NUT HAS LEFT THREAD CLUTCH WRENCH P N 10270 24m ALLEN WRENCH e INSTALL THE INNER WASHER see Fig 22 ATTENTION INSTALL WASHER WITH BEVEL TOWARDS SHAFT CLEAN ROLLER CAGE AND GREASE BEFORE INSTALLING IT ON CRANKSHAFT see Fig 23 f INSTALL CLUTCH DRUM AND EXTERNAL WASHER see Fig 24 ATTENTION INSTALL WASHER WITH BEVEL TOWARDS SHAFT Fig 21 Fig 22 Fig 23 Fig 24 ...

Page 21: ...S NOT ROTATE see Fig 25 AND TORQUE THE M1O NUT ON THE DRUM M10 NUT see Fig 26 TORQUE AT 30 40 Nm 265 350 lb in PISTON FITTING P N 10271 12 POINT WRENCH 17mm h REINSTALL CLUTCH COVER 3 SCREWS M6 see Fig 27 TORQUE AT 8 10 Nm 70 90 5mm ALLEN T TYPE Fig 25 Fig 26 Fig 27 ...

Page 22: ... 28 c INSTALL IGNITION ROTOR ON SHAFT WITH TIMING PLATE TOWARDS THE EXTERNAL see Fig 29 INSTALL SCREW AND NUT M10 TORQUE AT 20 26 Nm 175 230 in lb 12 POINT WRENCH 13mm d INSTALL STATOR 2 SCREWS M5X25 see Fig 30 4mm ALLEN T TYPE 9 e INSTALL IGNITION COVER 3 SCREWS M6X18 see Fig 32 5mm ALLEN T TYPE Fig 28 Fig 29 Fig 31 Fig 30 ...

Page 23: ...RT see Fig 32 b INSTALL COUNTERSHAFT SUPPORT COVER 3 SCREWS M6X20 see Fig 33 c INSTALL STARTER OIL OR AND PRESS STARTER IN SEAT MAKE SURE THAT GEARS ENGAGE 1 SCREW M6X16 1 SCREW M6X20 see Fig 34 d INSTALL STARTER SUPPORT ON ENGINE 4 SCREWS M6X45 see Fig 35 5mm ALLEN T TYPE Fig 32 Fig 33 Fig 34 Fig 35 ...

Page 24: ...LEN T TYPE 12 POINT WRENCH 10mm CONNECT PUMP INTAKE PRESSURE TO THE CRANKCASE FITTING see Fig 37 INSTALL THE CARB AND SECURE IT TO THE FITTING BY MEANS OF THE STEEL CLAMP see Fig 38 CONNECT THE CARB FUEL FITTING TO THE PUMP FITTING DELIVERY see Fig 39 Fig 36 Fig 37 Fig 38 Fig 39 ...

Page 25: ...MAN 045 ING 23 ...

Page 26: ...MAN 045 ING 24 CROSS PATTERN LOCKING ORDER ON CRANKCASE 7 3 1 5 2 6 4 ...

Page 27: ...d B on used conrod 0 01mm ATTENTION Play beween piston and liner must be 0 08mm If play is higher than 0 10mm replace piston Piston is measured at 15mm from bottom Size of the liner to be matched with piston is marked on top of piston with a green or red dot or with letter V or R If the size on piston top is marked with a green dot or with letter V the size marked on the piston matches with liner ...

Page 28: ...MAN 045 ING 26 ...

Page 29: ...kshaft plate crankshaft support crankpin pusher crankshaft insert 10100 C3 10103 10100 10107 10108 SPECIFIC TOOLS DRAWINGS ONLY Draw S725 3 ENGINE FIXING TOOL BEARING DISASSEMBLY TOOL BEARING ASSEMBLY TOOL CIRCLIP ASSEMBLY TOOL STANDARD TOOLS ALLEN WRENCH 4mm ALLEN WRENCH 5mm HEXAGON RING WRENCH 13mm 12 POINT WRENCH 12 POINT WRENCH 10mm 13mm 12 POINT WRENCH 17mm 12 POINT WRENCH 19mm HEXAGON RING W...

Page 30: ... FOR THE PROPER USE OF THE BATTERY CHARGER 1 Connect the red plug of the battery charger to the terminal red of the battery and the blue plug to the terminal black 2 plug in the battery charger to a 220V 50 HZ current tap 3 When charging the red led of the battery charger is lightened When the battery is fully charged the red led is off 4 Recharging time of a completely discharged battery approx 7...

Page 31: ...MAN 045 ING 29 Disegno S725 3 ...