IAME Parilla Norswift 60cc, Assembly Instructions & User Manual

Page 1: ...NORSWIFT 60cc MAN 033 01 11 04 MAN 071 ASSEMBLY INSTRUCTIONS USER MANUAL ...

Page 2: ...nstall the clutch cover 3 7 Electrical connection 3 8 Install the intake silencer 3 9 Install the exhaust system 4 Gasoline and Oil 5 Carburettor Adjustament guide 6 Starting and Stopping the engine 7 Engine Breaking In 8 Inlet Silencer 9 Recommendations on the exhaust system 10 Centrifugal Clutch 11 Instructions for the disassembly Assembly of the Clutch 12 Spark Plug Thermal Degree 13 Choice of ...

Page 3: ...ylinder with through studs The crankshaft is built and supported by ball bearings It s made of alloy steel hardened and tempered as well as the connecting rod which also undergoes a surface treatment of copper plating which rotates on roller bearings on both sides The ignition system is of analogical type with discharge capacity is powered by a flywheel and a coil whose functions are to generate t...

Page 4: ...he above limits no obligation of IAME exists in case the above limits are exceeded 1 CONTENTS OF PACKAGING Each engine NORSWIFT is supplied with the accessories shown below EXHAUST GROUP Quantity Exhaust Muffler Springs 2 Exhaust Manifold No restricted OR with restrictor Ø12 5mm 1 Exhaust Muffler 1 INLET GROUP Tillotson HL series Carburettor Ø19 8mm Ø16mm restricted 1 Intake Silencer with Fixing c...

Page 5: ...3 MAN 071 ILLUSTRATION OF ACCESSORIES EXHAUST GROUP SPARK PLUG NGK CLUTCH COVER TILLOTSON HL SERIES CARBURETTOR INTAKE SILENCER FIXING CLAMP INTAKE GROUP COIL SWITCH CABLE COIL WITH SPARK PLUG CAP ...

Page 6: ...to the coil see picture The number normally includes a letter followed by 4 digits Other numbers stamped on the crankcase or other surfaces refer to various manufacturing processes and do not identify the engine NOTE In case of need for spare parts and when contacting the IAME Support Centers please always supply to the Engine Identification Number and model ...

Page 7: ...er shown instructions for proper reassembly 3 1 EXHAUST HEADER ASSEMBLY NOTE THE ENGINE IS SUPPLIED WITH THE EXHAUST GASKET AND NUTS ALREADY INSERTED WHEN THE SHIPMENT IS MADE AN EXHAUST COVER GASKET IS PROVIDED TO PROTECT THE INTERNAL PARTS REMOVE THE EXHAUST COVER GASKET AND THE NUTS INSTALL SPRINGS ON THE EXHAUST HEADER SEE FIG 1 MAKE SURE THAT THE EXHAUST GASKET IS IN SEAT AND INSTALL THE EXHA...

Page 8: ...IMETERS DRILL 4 HOLES DIAM 8 5mm INTO THE MOTOR MOUNT INSTALL THE MOTOR MOUNT MAKE SURE TO USE M8 ALLEN SCREWS WITH A LENGTH SUCH AS TO ENGAGE IN THE CRANKCASE A THREADED PORTION LENGHT OF 16 19mm THE SCREW MUST PROTRUDE FROM THE PLATE FOR 16 19mm SEE FIG 5 AND DRAW 4 ALLEN SCREWS M8 TORQUE AT 22 24 Nm 190 210 in lb 6mm ALLEN WRENCH MOTOR MOUNT HORIZONTAL VIEW Fig 5 Fig 4 ...

Page 9: ... POINT WRENCH 10mm REMOVE THE 2 SCREWS 3 5mm ON THE CARB PUMP IN CORRESPONDENCE OF THE GAS CABLE BRACKET SEE FIG 7 SCREWDRIVER 4 8 mm TORX TOOL T20 INSERT THE GAS CABLE BRACKET THE 2 SCREWS AND TIGHTEN SEE FIG 8 INSTALL THE THROTTLE CABLE SPRING ON THE CARBURETTOR SEE FIG 9 Fig 9 Fig 7 Fig 6 Fig 8 ...

Page 10: ... KEEPING 1 CARBURETTOR GASKETS ON THE ENGINE INSTALL SEE FIG 11 12 N 2 THERMICAL SPACER N 2 CARBURETTOR GASKET CARBURETTOR N 2 NUTS M6 TORQUE AT 6 10 Nm 50 90 in lb 12 POINT WRENCH 10mm CONNECT BY APPROPRIATE PIPE THE INTAKE PRESSURE MANIFOLD ON THE CARBURETTOR AND THE INTAKE PRESSURE MANIFOLD ON THE CRANKCASE SEE FIG 13 Fig 13 Fig 13 Fig 10 Fig 11 Fig 12 ...

Page 11: ...HE CHAIN IS INSTALLED AND PROPERLY ALIGNED CHECK THE ALIGNMENT OF THE ENGINE SPROCKET AND THE AXLE SPROCKET WITH A STRAIGHT EDGE SEE FIG 15 INSTALL THE CHAIN PITCH 7 775mm SEE FIG 16 MOVE THE ENGINE ON THE RAILS AND OPTIMIZE THE CHAIN TENSION ATTENTION THE PLAY OF THE CHAIN MUST BE APPR 15mm inch MEASURED IN THE SHOWN POINT SEE FIG 17 TORQUE THE CLAMP SCREWS 15mm Fig 14 Fig 15 Fig 16 Fig 17 ...

Page 12: ...TION CONNECT THE COIL CABLE SMALL ONE TO THE TERMINAL ON THE COIL SEE FIG 20 CONNECT THE COIL CABLE AT THE TERMINAL ON THE ON OFF SWITCH SEE FIG 21 INSTALL THE SPARK PLUG ON THE CYLINDER HEAD AND INSTALL THE SPARK PLUG CAP MAKING SURE THAT THE SPARK PLUG CAP IS WELL INSERTED IN THE SPARK PLUG SEE FIG 22 HEXAGONAL PIPE WRENCH 20 8 TOURQUE SPARKPLUG AT 20 26 Nm 175 230 in lb Fig 22 Fig 19 FIG 20 Fig...

Page 13: ...PPERSIDE AND THAT THEY ARE NOT PLUGGED SEE FIG 23 TIGHTEN THE FIXING CLAMP ON THE CARB AND SUPPORT THE INTAKE SILENCER PROPERLY SEE FIG 24 3 9 INSTALL THE EXHAUST SYSTEM INSTALL THE EXHAUST MUFFLER ON THE MANIFOLD AND SECURE IT WITH THE 2 SPRINGS SEE FIG 25 THE ENGINE IS READY TO BE STARTED Fig 23 Fig 24 Fig 25 ...

Page 14: ...osits it is necessary to check and clean at least every 5 10 hours the piston and the cylinder head Our experience dictates use of oil such as WLADOIL RACING K2T Once the fuel tank is filled make sure that the gasoline reaches the carburettor before starting the engine ADVISE Disconnect the plastic tube from the carburettor and pressurize the vent tube on the tank until gasoline comes out from the...

Page 15: ... to approximately 1 T O I Close by further 1 T O after contact with throttle lever Start the engine and warm it If R P M too high adjust I counterclockwise until clutch is disengaged If R P M decreases Turn c c w until max R P M is reached Adjust further fractionally for rich idle Trigger accelerator L Slowly adjust clockwise If R P M increases Continue to turn clockwise until max R P M is reached...

Page 16: ...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 throttle if a tachometer is installed never exceed 8 000 RPM Never keep the same RPM for a long time 3 Progressively increase the speed of the kart for 5 minutes at throttle opening Never keep the same RPM for a long time 4 Increase the speed for 5 minutes at max ...

Page 17: ...d kart is still avoid useless accelerations which can overheat and deteriorate the clutch early Lubrificate the chain before each test immediately after each session and check the engine sprocket Replace if necessary A bad alignment between engine and axle sprockets or lack of lubrification will damage chain and sprocket Check the clutch Every 5 hours of use When metallic noises are heard from the...

Page 18: ...y for blocked the crankshaft Clutch wrench CH 24 Special tool S 1436 2 3 Remove drum nut 1 nut M10 12 Point wrench 17 mm 4 Remove the external washer the drum with roller cage the O Ring and the internal washer 5 Using the special tool and the clutch wrench CH24 remove the M16x1 nut and the cone safety washer ATTENTION Turn clockwise as nut has left thread Clutch wrench CH 24 Special tool S 1436 2...

Page 19: ... internal washer and the O ring ATTENTION install washer with chamfer towards internal part of engine Clean the roller cage and grease it before installing on the crankshaft 1 Install the clutch drum and the external washer ATTENTION install washer with chamfer towards internal part of engine 2 Using the special tool S 1436 2 or clutch wrench CH 24 and hooking itself to the clutch body for blocked...

Page 20: ... See table an excessively warm spark plug shows the symptoms listed aside ATTENTION Use a warmer spark plug with cold or rainy climates Extremely clear color porous look and calcification of the electrodes and of the internal insulator Irregularities in the ignition preignition and detonation with tendency to perforate the top of the piston Note some of these symptoms can be achieved also with lea...

Page 21: ...gine follow the under shown recommendations The engines are supplied with a 11 teeth sprocket pitch 7 775mm and you can also use 10 teeth sprocket Table 1 shows the various ratios between the sprocket on the axle and the engine sprocket given the different axle sprockets Sprocket ratio Teeth n Engine sprocket Sprocket ratio Teeth n Engine sprocket Teeth n Axle sprocket 10 11 Teeth n Axle sprocket ...

Page 22: ... laps on the track and let us assume that you read 11 000 max engine RPM From the table 2 to achieve a max RPM of 12 500 RPM operating limit for the NORSWIFT engine a sprocket ratio from 8 08 and 8 31should be used having used during the tests a sprocket ratio of 7 2 and having achieved 11 000 RPM max From table 1 with these values a sprocket ratio of 10 81 10 83 should be used or having a Z 11 on...

Page 23: ...ectors Check status and connections Engine mount and clamps Check torques After use Chain Check status and oil chain Engine External cleaning Engine used in rain conditions Clean carefully the engine interior and the clutch after lubrificate Every 5 10 hours Exhaust muffler Remove muffler end clean Inlet silencer Open clean Engine head Open clean Clutch Open and check status of parts Every 20 hour...

Page 24: ...djustment L screw Check carburettor adjustment see Sect 5 Drop in engine performance Bad compression Check piston Bad carburettor adjustment Check carburettor adjustment see Sect 5 Insufficient fuel flow Check fuel flow lines Dirty inlet silencer Check and clean Burning smell clutch smoke Overheating of clutch Check clutch Sect 10 11 Lubrificant accindentaly entered into the clutch Check clutch Se...

Page 25: ... period it must be preserved as follows Disconnect carburettor and clean it Seal with tape the engine inlet and exhaust The external of the engine must be cleaned Spray with protective oil the steel parts subject to oxidation Keep the engine in a dry ambient 17 FASTENER TORQUE TABLE ...