IAME GR-3 040/EM/12 User manual

0
GR-3 - 040/EM/12 - 60cc
USER MANUAL
MAN – 095-20 - EN

1
FEEDING
Fuel mixture 98 RON and 4% motor oil (CIK homologated).
We recommend:
- WLADOIL K 2T ;
- ELF HTX 909 ;
- ELF HTX 976 ;
- EXCED RSK M.
PREPARING THE MOTOR MOUNT
To fix the engine onto the chassis it is necessary to make holes on the motor
mount with the following dimensions:

2
ELECTRIC SYSTEM
The engine is provided with homologated digital ignition. The advance has to be
set to 2.60mm before TDC, corresponding to 26°~.
The spark point is where the markings on both rotor and stator match.
Please take particular care to the ground connection between the coil’s
steel body and the appropriate screw on the clutch cover.

3
MAIN ENGINE COMPONENTS’ MAINTENANCE INTERVALS
The components’ lifetime can change according to the engine use.
PISTON / CYLINDER MATCHING
The piston has to be replaced when the measured clearance exceed 0.11mm.
As a general prescription, we recommend to replace it after an approximate
consumption of 60 litres.
The size marked on the top of the piston is the diameter of the cylinder bore
where the piston has to be installed.
The prescribed clearance, provided within the piston when brand new, is
0.07÷0.08mm.
This is reached by honing the cylinder at the same diameter marked on the piston
top, for the green selection, or adding 0.01mm to the diameter marked on the
piston top, for the red selection.
The effective piston diameter can be verified measuring perpendicularly to the
piston pin at 15mm from piston base.
The gap between the piston ring tips (installed into the cylinder) must be between
0.05÷0.15 mm.
The gap can be checked with a feeler gauge, by inserting the ring into the cylinder.

4
MAIN BEARINGS
With the roller bearings, the lifetime is a full sporting season.
CONROD BIG END CAGE, CRANKPIN and WASHERS
The replacement must be performed after an approximate consumption of 120lt
of fuel.
CONROD SMALL END CAGE
The replacement must be performed after an approximate consumption of 120lt
of fuel.
CONROD
We recommend to replace the conrod when the ovalization of big end bore
exceeds 0.01mm. This value is the difference between the diameter measured in
"A" and "B" as below indicated.
As a general prescription, we recommend to replace it after an approximate
consumption of 240 litres.

5
IDLE RPM
SCREW
“M”
IDLE
MIXTURE
SCREW
CARBURETTOR SETTING
The carburettor is supplied with a standard setup. Please find the standard setup
reported below.
The carburettor setup has to be adjusted in function of track and weather
conditions, acting on the setup parts available.
DELLORTO PHBG 18 BASIC SETUP
To set the engine idle RPM, act on screw “M”.
Turn counter clockwise to decrease RPM and clockwise
to increase.
EXAMPLE OF RACING SETUP
FUEL PUMP CONNECTIONS
CONICAL NEEDLE
W23 - 2ª NOTCH FROM TOP
GAS THROTTLE
40
ATOMIZER
AU 262
MAXIMUM JET
68
IDLE JET
60
STARTER JET
60
IDLE MIXTURE SCREW
1 TURN
CONICAL NEEDLE
W1 - 2ª NOTCH FROM TOP
GAS THROTTLE
50
ATOMIZER
AU 262
MAXIMUM JET
64
MINIMUM JET
65
STARTER JET
60
IDLE MIXTURE SCREW
2 TURNS
Delivery to carburettor
without fuel return to
the tank
Breather
(from crankcase)
Inlet
(from tank)

6
TECHNICAL DATA SUMMARY TABLE
DESCRIPTION
DATA
FUEL MIXTURE / FUEL
4% OF OIL
FUEL 98 RON
Oil CIK homologated
LIMIT PORT TIMING
Exhaust 156° (0°/-2°)
Transfers 114° (0°/-2)
Inlet 144° (0°/-2)
Feeler gauge 0.2x5mm
TIMING ADVANCE 2.60 mm
Before TDC
COMBUSTION CHAMBER VOLUME 7 cm³
(min. 6.80cm³)
SQUISH 0.52÷0.55mm
measured with single wire d.1.5mm
PISTON RING GAP 0.05 ÷ 0.15 mm
Installed into the cylinder
AXIAL SHAFT CLEARANCE (END FLOAT) 0.40 ÷ 0.50 mm
SPARK PLUG FOR STANDARD WEATHER
CONDITIONS NGK BR 10 EG
SPARK PLUG FOR RAIN CONDITIONS NGK BR 9 EG