IAME Parilla MINI SWIFT User manual

12/10/05 MAN-045 ING
1
ENGINE OVERHAULING
MANUAL
60cc BABY
&
MINI SWIFT
- TaG

12/10/05 MAN-045 ING
2
INDEX
Page
1. - ENGINE DISASSEMBLY 1
2. - CRANKSHAFT ASSEMBLY / DISASSEMBLY 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

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1 – ENGINE DISASSEMBLY
OPERATION TOOLS REQUIRED
1.
INSERT TWO SCREWS M8X60 ON THE
CRANKCASE TO POSITION MOTOR ON THE
BENCH.
VICE ON BENCH (tool as 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)
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- REMOVE PISTON FITTING AND USING
CLUTCH WRENCH REMOVE THE FIXING
NUT.
(see Fig.4)
(CLUTCH WRENCH: P.N. 10270)
(12 POINT WRENCH - 24mm)
ATTENTION:
TURN CLOCKWISE AS NUT HAS LEFT
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)
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4.
REMOVE THE IGNITION:
-REMOVE STATOR .
2 SCREWS M5X25 (see Fig.8).
(5mm ALLEN T TYPE)
-INSTALL PISTON 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).
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-REMOVE THE COUNTERSHAFT SUPPORT
COVER .
3 SCREWS M6X20 (see Fig.13).
-EXTRACT THE COUNTERSHAFT FROM
THE SUPPORT.
(see Fig.14).
6.
REMOVE THE HEAD :
-LOOSEN NUTS BY ½ TURN (CROSS
PATTERN DISASSEMBLY) AND THEN
REMOVE (see Fig.15).
4 NUTS M8
4 WASHERS
(13mm SOCKET T- TYPE)
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7.
REMOVE CYLINDER (see Fig.16).
REMOVE CYLINDER GASKET.
8.
REMOVE CIRCLIPS FROM PISTON
(see Fig.17)
(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).
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REMOVE THE PUMP FIXING SCREWS
(see Fig.20).
2 SCREWS M6X45
1 NUT M6
(5mm ALLEN T TYPE)
(6 POINT WRENCH - 10mm)
11.
OPENING THE CRANKCASE:
-REMOVE 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.
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2 – CRANKSHAFT ASSEMBLY/DISASSEMBLY
ATTENTION:
THE DISASSEMBLY/ASSEMBLY OPERATIONS ON THE ENGINE CRANKSHAFT, MUST BE
PERFORMED ONLY BY AN AUTHORIZED SUPPORT CENTER USING THE SPECIALLY DESIGNED
TOOLS. USE OF UNFITTED TOOLS OR OPERATIONS PERFORMED BY UNSKILL PERSONNEL
MAY DAMAGE THE CRANKSHAFT BEYOND REPAIR.
TOOLS DESCRIPTION P.N.
CRANKSHAFT ASSEMBLY KIT 10110-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) BETWEEN THE CRANKSHAFT
HALVES (see Fig.1).
3.
INSERT THE CRANKSHAFT INSERT 60cc
(P.N. 10108) AND USING THE CRANKPIN
PUSHER (P.N. 10107) PRESS THE
CRANKPIN OUT (see Fig.2).
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4.
DISASSEMBLE THE CON-ROD WITH
WASHERS.
REPEAT THE OPERATIONS TO EXTRACT
THE CRANKPIN FROM THE OTHER HALF
CRANKSHAFT (see Fig.3).
BEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE
a) CHECK STATUS OF CON-ROD (TOP
AND BOTTOM) .
IF OVALIZATION 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 ATTACHED TABLE FOR MATCHING PLAYS
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2.2 – CRANKSHAFT ASSEMBLY
OPERATION TOOLS REQUIRED
1. PLACE THE CRANKSHAFT ASSEMBLY
TOOL (P.N. 10110-C) UNDER THE PRESS,
VERTICALLY - 5 MeT PRESS
- CRANKSHAFT 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).
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7.
EXTRACT BUSH FROM CRANKPIN AND
PUT TOOL IN HORIZONTAL POSITION (see
Fig.4).
8.
INSERT ON CRANKPIN (OIL 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).
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11. OIL CRANKPIN AND CRANKPIN HOLE ON
CRANKSHAFT HALF .
12.
PUT TOOL IN VERTICAL POSITION
(see Fig.8).
13. PROGRESSIVELY PRESS THE TWO
CRANKSHAFT HALVES TOGETHER.
14. OPEN THE TOOL. PUT IT IN HORIZONTAL
POSITION AND EXTRACT THE
CRANKSHAFT.
15.
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
-COPPER HAMMER FOR ALIGNMENT
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b.
ROTATE CRANKSHAFT AND LOOK AT
DEFLECTION OF GAUGE NEEDLES.
DEFLECTION MUST BE, AFTER CENTERING
MAX. 0.01mm (see drawing).
c.
ADJUST CENTERING 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).
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d) INSERT BALL-BEARINGS TO BE ON
UPPER SIDE AND OIL WHEN
ASSEMBLING .
USE TOOL AS PER DRAWING S725/3
(see Fig.2/3).
-SPECIAL 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)
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ATTENTION:
AS FIRST STEP, ASSEMBLE CRANKCASE
WITH 4 SCREWS AND CHECK CRANKSHAFT
AXIAL PLAY TO BE 0.20 ±0.05mm.
IF LOWER OR HIGHER, DISASSEMBLE THE
CRANKCASE, EXTRACT THE BEARINGS AND
USE DIFFERENT SHIMS (0.10/0.15/0.20).
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
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INSERT OIL SEALS .
USE TOOL AS PER DRAWING S725/3
(see Fig.10).
(MARK ON THE OIL SEAL MUST BE TOWARDS
THE EXTERNAL).
ATTENTION:
THE OIL SEAL MUST BE REPLACED AFTER
MAX. WORKING 6 HRS AND ALWAYS WHEN
REMOVED.
INSTALL PISTON :
a) CHECK STATUS OF THE ROLLER CAGE.
IT MUST BE REPLACED AFTER MAX. 4
WORKING HRS.
b) CHECK STATUS OF PISTON PIN
REPLACE THE PISTON PIN WHEN
REPLACING PISTON.
(SEE ATTACHMENT ON MATCHING
SELECTIONS BETWEEN CONROD /
PISTON PIN / ROLLER CAGE).
c) INSTALL RING ON THE PISTON
(see Fig.11).
ATTENTION:
CHECK 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 CHANGE PISTON COMPLETE WITH
RINGS.
3.
e) IINSERT PISTON PIN AND ROLLER CAGE
IN THE PISTON (see Fig.13).
MAKE SURE THAT ARROW ON TOP OF
PISTON IS TOWARDS EXHAUST.
AS A GENERAL RULE, PISTON PIN MUST
BE FORCED IN HOLE. IF PISTON PIN IS
LOOSE IN SEAT, REPLACE IT WITH A
HIGHER DIAMETER PIN.
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f) PLACE CIRCLIP ON TOOL
GREASE TOOL, TO KEEP CIRCLIP IN
PLACE.
(see Fig.14).
g) INSERT CIRCLIP
(see Fig.15).
CHECK THAT CIRCLIPS ARE IN SEAT.
-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
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BEFORE ASSEMBLING THE CLUTCH , WASH WITH DILUENT THE SHAFT TAPER, THE CONNECTING HOLE ON
THE CLUTCH BODY, THE CLUTCH DRUM AND STARTER RING .
INSTALL THE CLUTCH :
a) INSTALL THE STARTER RING ON THE
CLUTCH 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).
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d) INSTALL THE CLUTCH BODY FIXING
NUT USING THE CLUTCH WRENCH
(see Fig.21).
TORQUE AT 40÷50 Nm ( 350÷440 in-lb).
ATTENTION:
TORQUE COUNTERCLOCKWISE AS 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 .
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