IAME Parilla Reedster 125cc, Overhauling Manual

Page 1: ...07 11 07 MAN 052 1 OVERHAULING MANUAL REEDSTER 125cc versions F1 F2 F3 F4 21 01 2009...

Page 2: ...FT DISASSEMBLY 13 2 2 CRANKSHAFT ASSEMBLY 15 3 REEDSTER 125cc ENGINE ASSEMBLY 18 ATTACHMENTS FASTENER TORQUE TABLE CROSS PATTERN LOCKING ORDER ON CRANKCASE MAIN PRESCRIPTIONS CONROD BIG END AND SMALL...

Page 3: ...O FACILITATE OIL DISCHARGINGAND CHECK THAT THE GEARBOX BREATHER IS FREE AND see Fig 2 2 FIX THE ENGINE ON THE BENCH VICE SCREW N 2 SCREWS M8x30 IN THE CRANKCASE TOOL FOR BENCH VICE see attached drawin...

Page 4: ...4 4mm ALLEN WRENCH T TYPE REMOVE SPARKPLUG AND INSTALL THE SPECIAL PISTON RETAINER P N 10271 TO LOCK THE CRANKSHAFT see Fig 5 REMOVE NUT M12 see Fig 6 17mm SOCKET WRENCH EXTRACT ROTOR WITH THE SPECIAL...

Page 5: ...P OF A PLASTIC MALLET IF NECESSARY ATTENTION PAY ATTENTION NOT TO DAMAGE THE OIL SEAL LIP 6 REMOVE STARTER UNLOOSE N 4 SCREWS M6x35 see Fig 10 5mm ALLEN WRENCH T TYPE REMOVE STARTER see Fig 11 NOTE TH...

Page 6: ...Fig 13 5mm ALLEN WRENCH T TYPE REMOVE STARTER COUNTERSHAFT COVER UNSCREW N 3 SCREWS M6x25 see Fig 14 5mm ALLEN WRENCH T TYPE REMOVE PISTON RETAINER FROM HEAD AND INSTALL THE STARTER RING LOCKING TOOL...

Page 7: ...AD REMOVE THE CLUTCH BODY AND THE STARTING GEAR FROM THE CRANKSHAFT BY MEANS OF THE CLUTCH DISASSEMBLY TOOL P N 10272 C see Fig 17 19mm and 27mm SOCKET WRENCHES REMOVE STARTER GEAR FROM THE CLUTCH BOD...

Page 8: ...UNSCREW N 4 SCREWS M6x20 see Fig 20 5mmALLEN WRENCH T TYPE REMOVE COVER AND WASHER see Fig 21 INSTALL THE GEAR LOCKING TOOL P N ATT 008 see Fig 22 UNSCREW SCREW M5X20 AND REMOVE PUMP IMPELLER see Fig...

Page 9: ...FT see Fig 25 27mm SOCKET WRENCH REMOVE THE GEAR LOCKING TOOL REMOVE GEAR FROM THE CRANKSHAFT USE THE PULLER P N ATT 010 IF NECESSARY see Fig 26 19mmSOCKET WRENCH ATTENTION MARK THE GEAR WITH A FELT P...

Page 10: ...ATTENTION NOT TO DAMAGE THE OIL SEAL LIP 11 REMOVE THE CARB INLET DUCT UNSCREW N 4 SCREWS M6x25 see Fig 29 5mm ALLEN WRENCH T TYPE REMOVE DUCT REED GROUP AND WASHERS see Fig 30 12 REMOVE EXHAUST VALVE...

Page 11: ...NING SPRING see Fig 32 UNSCREW N 2 SCREWS M6 see Fig 33 5mm ALLEN WRENCH T TYPE EXTRACT THE VALVE FROM THE CYLINDER vedi Fig 34 UNSCREW COMPLETELY THE SLIDE BY HAND AND REMOVE IT FROM ITS SEAT see Fig...

Page 12: ...D REMOVE IT see Fig 37 CLEAN CAREFULLY THE VALVE PARTS AND REMOVE THE EXHAUST GAS AND OIL RESIDUES see Fig 38 ATTENTION DO NOT USE AN AGGRESSIVE DEGREASER TO AVOID DAMAGING THE RUBBER PARTS 13 REMOVE...

Page 13: ...1 SCREWDRIVER WITH ROUNDED EDGE ATTENTION PAY ATTENTION NOT TO SCRATCH THE PISTON AND CIRCLIPS SEAT REMOVE PISTON PIN BY USING THE SPECIAL PISTON PIN PUNCH TOOL P N 10200 see Fig 42 REMOVE PISTON REMO...

Page 14: ...F NECESSARY 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...

Page 15: ...ERFORMED BY UNSKILLED PERSONNEL MAY DAMAGE THE CRANKSHAFT BEYOND REPAIR TOOLS DESCRIPTION P N CRANKSHAFT ASSEMBLY TOOL 10110B C CRANKPIN BUSH INCLUDED IN 10110B C 10150A CRANKSHAFT DISASSEMBLY TOOL KI...

Page 16: ...OF CON ROD TOP AND BOTTOM IF OVALIZATION EXCEEDS 0 01mm REPLACE CON ROD 0 001 BORE GAUGE WITH CHECK RING 26 AND 19 b CHECK STATUS OF CRANKPIN VISUAL CHECK REPLACE IF NECESSARY REPLACE AFTER 30 WORKIN...

Page 17: ...LLY PRESS 5 MeT 2 PLACE THE CRANKSHAFT INTO THE ASSEMBLY TOOL 3 OIL CRANKPIN HOLE ON CRANKSHAFT HALF 4 PLACE CRANKPIN WITH CRANKPIN BUSH P N 10150A ON CRANKSHAFT HALF see Fig 1 5 BRING UPPER PLATE OF...

Page 18: ...ROM FALLING WHEN INSERTING THE CAGE ON THE CRANKPIN 8 PLACE CLAMP JIG IN HORIZONTAL POSITION AND PLACE HALF CRANKSHAFT see fig 5 9 PLACE THE SECOND CRANKSHAFT IN THE COUNTERPLATE SEAT see Fig 6 10 BRI...

Page 19: ...XIAL PLAY OF THE CON ROD see Fig 9 IT MUST BE MIN 0 4mm MAX 0 7mm IF PLAY IS HIGHER OR LOWER REBUILD THE CRANKSHAFT AFTER ASSEMBLING THE CRANKSHAFT IT MUST BE ALIGNED OTHERWISE EXCESSIVE VIBRATIONS HA...

Page 20: ...awing c 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 1 INSTALLING BEARINGS INSERT...

Page 21: ...THE INNER BALANCE SHAFT BEARING BALLS TO BE ON UPPER SIDE GREASE BALLS BEFORE ASSEMBLING OIL THE BEARING EXTERNAL AND THE HALF CRANKCASE SEAT USE THE SPECIAL TOOL P N 10292 TO INSERT THE BEARING see...

Page 22: ...EMBLE CRANKCASE WITH 4 SCREWS AND CHECK CRANKSHAFT AXIAL PLAY TO BE 0 20 0 25mm IF PLAY IS LOWER OR HIGHER DISASSEMBLE CRANKCASE EXTRACT BEARINGS AND USE DIFFERENT STEEL SHIMS 0 10 0 15 0 20 TO RECOVE...

Page 23: ...D INNER OIL SEAL LIPS ATTENTION WHEN FITTING NEW SEALS TURNING THE CRANKSHAFT COULD RESULT MORE DIFFICULT BUT THIS IS NORMAL FIT SEALS ON CRANKSHAFT BY USING THE SPECIAL TOOL WITH BUSHING TO BE INSERT...

Page 24: ...GEARS CHECK THE GEAR TEETH GOOD STATUS INSERT THE BELLEVILLE WASHER ON THE BALANCE SHAFT AND LOCATE THE GEAR 5TR SIDE LETTERS A AND C TO BE VISIBLE BEING CAREFUL TO ALIGN THE REFERENCE NOTCHES ON THE...

Page 25: ...ENCH WITH 27mm BUSH 5 ASSEMBLING THE WATER PUMP ASSEMBLE THE WATER PUMP IMPELLER SCREW M5x20 see Fig 19 TORQUE AT 5 6 Nm 45 55 lbf in 8mm SOCKET WRENCH ATTENTION THE SHAFT DRAGGING SURFACES MUST MATCH...

Page 26: ...T TYPE ATTENTION THE COPPER WASHER MUST BE PLACED UNDER THE OIL DISCHARGING SCREW 8 CHARGING OIL IN THE GEARBOX PUT THE ENGINE PERFECTLY HORIZONTAL REMOVE OIL BREATHER FROM CRANKCASE see Fig 23 11mm...

Page 27: ...REPLACE PISTON RING WHEN PLAY EXCEEDS 0 4mm ATTENTION PLAY BETWEEN PISTON AND LINER MUST BE BETWEEN 0 11 0 12mm IF PLAY EXCEEDS 0 14mm REPLACE PISTON FOLLOW INSTRUCTIONS ON THE ATTACHMENT FOR PROPER M...

Page 28: ...TORQUE AT 18 22 Nm 160 195 lbf in 12mm SOCKET WRENCH PLACE THE O RINGS see Fig 32 ON INTERNAL OF CYILINDE ON EXTERNAL OF CYLINDER ON TIE RODS 11 INSTALLING THE CYLINDER HEAD CLEAN COMBUSTION CHAMBER F...

Page 29: ...D AND INSERT M12 NUT ON SHAFT see Fig 35 TORQUE AT 20 26 Nm 175 230 lbf in 17mm SOCKET WRENCH INSTALL STATOR N 3 SCREWS M5x25 see Fig 36 NOTE DO NOT TIGHTEN THE SCREWS TO END BEFORE HAVING ADJUSTED TH...

Page 30: ...3 4 1mm for F4 see Fig 38 PREVENTING THE CRANKSHAFT FROM TURNING ROTATE IGNITION STATOR UNTIL THE REFERENCE NOTCH MATCHES TOGETHER WITH THE NOTCH ON ROTOR see Fig 39 FIX STATOR N 3 ALLEN SCREWS M5x25...

Page 31: ...KICKBACKS COULD BREAK THE SCREWS APPLY LOCTITE 641 ON THE TAPER SHAFT FOR COAXIAL LOCKINGS see Fig 43 INSTALL THE STARTER RING WITH CLUTCH BODY ON CRANKSHAFT INSTALL THE STARTER RING LOCKING TOOL NUT...

Page 32: ...AINING NUT 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 COUNTERSHAFT COVER see Fig 48 N 3 SCREWS M6x25 TORQUE AT A 6 8 Nm 5...

Page 33: ...ECK BEFORE THE STATUS OF REED PETALS IF REED PETALS ARE SCRATCHED OR IF LOOKING THROUGH THE REED GROUP AGAINST THE LIGHT THE PETALS DO NOT CLOSE PERFECTLY REPLACE THEM REMOVE N 8 SCREWS AND PLACE REED...

Page 34: ...NE ON THE VALVE BODY CHECK THE DISTANCE BETWEEN THE SLIDE LOWER MID PART AND THE HEAD UPPER PART PROPER DISTANCE MUST BE 86 5mm see Fig 56a STARTING FROM THE VALVE 09 MODEL THE CORRECT VALUE IS OF 85...

Page 35: ...H T TYPE PLACE SPRING ON THE VALVE PISTON AND INSTALL COVER CHECKING THAT SPRING IS COMPLETELY IN SEAT see Fig 59 KEEP COVER IN POSITION AND SECURE IT WITH STEEL CLAMP CHECK THAT THE CLAMP END IS PROP...

Page 36: ...MAN 052 34 COUPLES ON TIGHTENING OF NUTS AND SCREWS...

Page 37: ...MAN 052 35 CROSS PATTERN LOCKING ORDER ON CRANKCASE...

Page 38: ...mm from the base The piston size is marked on the top with a green or red dots or with the letters V or R If the size on piston top is marked with a green dot or letter V add 0 11mm to size marked on...

Page 39: ...MAN 052 37...

Page 40: ...SASSY TOOL OIL SEAL ASSEMBLY TOOL without crankshaft OIL SEAL ASSEMBLY TOOL with installed crankshaft GEAR COVER OIL SEAL ASSEMBLY TOOL WATER PUMP OIL SEAL ASSEMBLY TOOL 10291 10293 10290 10292 10295...

Page 41: ...NCE SHAFT EXTERNAL BEARING SEAT MICROMETER 0 25 1 100 MIN 24 96 BALANCE SHAFT INTERNAL BEARING SEAT MICROMETER 0 25 1 100 MIN 14 96 CRANKSHAFT BEARINGS 1 100 BORE GAUGE WITH CHECK RING 25 MAX 25 03 BA...

Page 42: ...MAN 022 40 FIXING ENGINE TOOL ON BENCH VICE 40...