IAME REEDJET 100cc, Overhaul Manual

Page 1: ...REEDJET 100cc MAN 086 EN OVERHAUL MANUAL...

Page 2: ...CRANKSHAFT ASSEMBLY OPERATIONS 8 ENGINE ASSEMBLY 10 ATTACHMENTS FASTENER TORQUE VALUE 20 CROSS PATTERN LOCKING ORDER ON CRANKCASE 20 MAIN PRESCRIPTIONS 21 WEAR STATUS EVALUATION TABLE FOR BEARING AND...

Page 3: ...ert n 2 screws M8x60 on bottom of crankcase to position and fix motor on bench TOOLS FOR VISE ON BENCH FOR TOOL SEE ATTACHED DRAWING S725 1 Remove Spark Plug Unscrew with 20 8mm SOCKET WRENCH T TYPE e...

Page 4: ...n 2 washers the exhaust manifold and its gasket Remove The Clutch Cover Unscrews n 3 M6x30 TCEI with 5mm ALLEN WRENCH T TYPE Remove The Clutch Unscrew the Bendix cover with 5mm ALLEN WRENCH T TYPE an...

Page 5: ...her and O ring With the starter wheel locking tool and SOCKET WRENCH 27mm remove the M20x1clutch hub nut WARNING USCREW CLOCKWISE AS THE NUT HAS LEFT HAND THREAD Remove the clutch hub and the starter...

Page 6: ...photo The important fact is that the ATT 037 STARTER WHEEL LOCKING TOOL is in place on the crankcase Remove the ignition Nut M10 with the Ring Wrench 17mm Remove the Rotor Remove the Stator unscrew n...

Page 7: ...h ALLEN WRENCH 5mm T TYPE Remove the other components of inlet system as in picture Remove the Cylinder Head Unscrew Head Nuts n 2 Nuts M8 and n 2 Column nuts with SOCKET WRENCH 13MM T TYPE Remove Cyl...

Page 8: ...ges ATTENTION DO NOT SCRATCH PISTON OR CIRCLIP SEATS Remove Piston Pin Piston and Cage Using the PISTON PIN PUNCH P N 10200 Remove Starter Group Untighten the screws that fix the starter support to th...

Page 9: ...ls Bearing if necessary Use a SCREWDRIVER for Seals For the bearing heat crankcase half to 70 or use press and special pusher as in picture S725 1 N B Remove and preserve Shims CRANKSHAFT DISASSEMBLY...

Page 10: ...WILL BE REASSEMBLED WITHOUT SUBSTITUTION THEY MUST BE PLACED IN THE SAME SENSE POSITION AS BEFORE WE SUGGEST TO MARK CONROD AND WASHES BEFORE DISASSEMBLE AND PARTICULAR ATTENTION HAS TO BE PAID TO THE...

Page 11: ...put in horizontal position After having lubricated crankpin insert the silver washer the conrod with roller cage and the other silver washer ATTENTION ROLLERS ARE FREE IN THE CAGE PREVENT ROLLERS FRO...

Page 12: ...WER REBUILD THE CRANKSHAFT AFTER ASSEMBLY THE CRANKSHAFT MUST BE ALIGNED OTHERWISE EXCESSIVE VIBRATION HARD STARTING OR POOR ACCELERATION WILL RESULT Place the crankshaft between the centres with dial...

Page 13: ...positioned in the original installation and close temporarily the crankcase for axial clearance check Fixing the crankcase with only 3 4 screws with 5mm ALLEN WRENCH T TYPE In this step tighten the s...

Page 14: ...to clean eventual excess of product Lubricate crankshaft seat before insertion prevent oil from falling onto liquid gasket Reassemble crankcase Fixing n 7 Screws n 5 M6x45 n 3 M6x60 tighten with ALLEN...

Page 15: ...NESS GAUGE MEASURE THE END GAP OF THE PISTON RING WHEN INSERTED IN THE CYLINDER GAP SHOULD BE 0 15 0 40 REPLACE THE PISTON RING IF THE END GAP EXCEEDS 0 50mm Install ring on the piston ATTENTION CLEAR...

Page 16: ...replace it with a higher diameter pin Using piston pin punch as guide Position Circlip On Tool Grease tool to keep circlip in place use TOOL P N 10120 insert circlips and check that both the circlips...

Page 17: ...e the starter wheel and the clutch drum Assemble the starter wheel on the clutch hub tighten n 3 M6 TCEI with ALLEN WRENCH 5mm T TYPE 10 12 Nm 90 110 lb in and the dragging pin Apply Loctite thread lo...

Page 18: ...AS LEFT HAND THREAD Assemble the internal washer the bevel of the washer hole must be towards the shaft Install the O Ring Clean the roller cage and grease it before assembling it on the shaft Mount t...

Page 19: ...70 90 lb in Grease the Bendix cage insert the Bendix and fit the cover n 3 M6x25 with 5mm ALLEN WRENCH T TYPE torque at 6 8 Nm 55 70 lb in Installation of the Starter Support Place the support on the...

Page 20: ...TOOL in position Then remove ATT 037 STARTER WHEEL LOCKING TOOL and install the Bendix cover Tighten n 3 M6x25 with 5mm ALLEN WRENCH T TYPE torque at 6 8 Nm 55 70 lb in Install the ignition stator on...

Page 21: ...Rotate the stator until the two marks on rotor and stator match Fix stator with n 2 screw TCEI M5x25 with 4mm ALLEN WRENCH T TYPE torque at 5 6 Nm 45 55 lb in Ignition timing is completed Install the...

Page 22: ...UT PERFECTLY LOOSEN THE N 8 SCREWS AND INSERT NEW PETALS WITH BOTTOM CUT TOWARDS RIGHT Position the reed pack and its gasket install the reed pack group into the inlet seat of the engine with IAME mar...

Page 23: ...45 50 M5x0 8 2 Ignition Stator Fixing Screws Allen 4 5 6 45 50 M10x1 1 Ignition Rotor Fixing Nuts Hex 17 20 26 175 230 M6x1 3 Bendix Support Cover Screws Allen 5 6 8 55 70 M6x1 4 Bendix Support Screws...

Page 24: ...e carried out after about 30 hours use When ovalization reaches 0 01mm the difference between the measured diameter in the positions shown below A and B the conrod must be replaced The replacement ope...

Page 25: ...PART MEASURING INSTRUMENT LIMITS Replace after Hours for Using CRANKSHAFT BEARING SEAT MICROMETER 25 50 1 100 MIN 24 96 DEPENDING ON WEAR RATE CRANKSHAFT BEARINGS 1 100 BORE GAUGE WITH CHECK RING 25 M...

Page 26: ...MAN 086 ENG 25 OVERHAUL TOOL LIST 23...

Page 27: ...rt 10100 C2 10104A 10100 10107 10106 TIMING CHECK TOOL VOLUMETER 10192 ATT 063 2 STATOR CENTERING TOOL ATT 065 SPECIFIC TOOLS DRAWINGS ONLY Draw S725 1 ENGINE FIXING TOOL BEARING DISASSEMBLY TOOL BEAR...

Page 28: ...MAN 086 ENG 27 Drawing S725 1 MATERIAL Steel Fe 50 UNI 5332 25...

Page 29: ...MAN 086 ENG 28 WIRING DIAGRAM 26...

Page 30: ...MAN 086 ENG 29 1 Start Stop button 2 Battery 3 Ignition adapter 4 Starter 5 H T Coil 6 Ignition 27...