IAME Parilla Norswift 60cc Owner's manual

NORSWIFT 60cc
MAN-033
01/11/04
MAN-071
ASSEMBLY INSTRUCTIONS & USER MANUAL

1 MAN-071
INDICE
GENERAL DESCRIPTION OF ENGINE
ENGINE CHARACTERISTICS –OPERATIONAL LIMITS
1- Contents of packaging
2- Engine Identification Number
3- Preparation and installation of the engine on the chassis
3.1 Exhaust Header Assembly
3.2 Preparation and installation of the motor-mount
3.3 Assembling the carburettor
3.4 Installation of the carburettor
3.5 Install the engine on the chassis
3.6 Install 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 the best sprocket ratio
14- Scheduled Maintenance
15- Troubleshooting
16- Engine Preservation
17- Fasterner Torque table
N° PAG.
1
2
2
4
5
5
6
7
8
9
10
10
11
11
12
13
14
14
14
15
15
16
18
19
21
22
23
23

GENERAL DESCRIPTION OF ENGINE
This engine is for propaedeutic series and for young drivers and has been specifically
designed and developed for powering of kart, either for racing purposes and hobby, but
always on closed tracks.
During the design phase has been inspired to the technical solutions already adopted for
high-performance engines kart, to its simplicity of installation and use, related to a
parsimonious maintenance, in order to ensure the maximum durability and reliability of the
components, subject to compliance with the operational limits.
The engine is single-cylinder and uses the principle OTTO two stroke.
The cylinder and the crankcase are made in aluminium alloy.
The pressed-in lineris made of centrifuged cast iron, fully machined from a solid to ensure
the best stability and homogeneity of sliding.
The head is separated from cylinder and is secured to the cylinder 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 the spark energy required for a proper
management of goodwill, provide the references phase by a pick-up integrated.
The plant comprises a rotor-stator, a high voltage coil, which allow the control of the
advance.
The engine is equipped with a pull starter. Repeatedly pull the starter handle until the engine
start.
The engine is also equipped with a centrifugal dry clutch with low maintenance with
incorporated sprocket.
The carburettor type is a diaphragm (series Tillotson HL) includes an integrated fuel pump
and filter, and is able to operate in any position.
The exhaust system, including in the supply, is already tuned and optimized to ensure the
best possible performance.
1 MAN-071

2 MAN-071
ENGINE CHARACTERISTICS
The Characteristic of the engine are the following:
Cycle:
Original cubic capacity
Original bore:
Max. Theorical bore:
Stroke:
Lubrification :
Inductiion:
Carburettor:
Cooling:
Ignition:
Clutch:
Starting:
OTTO / 2 Stroke Single Cylinder
59.42 cm³ (60.00 cm³ max)
41.80 mm
42.00 mm
43.30 mm
Fuel-oil mix / oil 3%
Piston Port
Diaphragm type, Tillotson HL series
Air
Analogical
Automatic, 3-mass Centrifugal Dry
Pull Start
OPERATIONAL LIMITS:
Max. RPM / 1’: 12.500 RPM (Without limiter)
ATTENTION:
Never exceed the 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 clamp
1
Intake Silencer Support
1
Gas cable bracket with accessories
1
Thermal Spacer + Gaskets
2+3
Fuel Pipe
1
ELECTRIC GROUP
H.T. Coil (Assembled on to the engine)
1
Kill Switch + Switch Bracket (Assembled on to the engine)
1+1
Connective Cable H.T. Coil to Switch
1
Sparkplug NGK BR 9 EG
1
MISCELLANEUOS
Clutch Cover
1

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

4 MAN-071
2- ENGINE IDENTIFICATION NUMBER
The official identification number can be found stamped on the left lower part of the
crankcase (pull start side), next 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.

5 MAN-071
3- PREPARATION AND INSTALLATION OF THE ENGINE ON THE CHASSIS
NOTE:
In case the engine is supplied already assembled on to the chassis, it is at care of the assembler to follow these
instructions. The final customer, in this case, can skip this section and can start reading from section 4.
Whenever the engine or a component is disassembled, it is necessary to always follow the under 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 EXHAUST HEADER.
(SEE FIG. 2)
-INSTALL THE 2 WASHERS 6mm
(SEE FIG. 3)
SUGGESTION:
PUT THE ENGINE IN HORIZONTAL POSITION
(USE A SCREWDRIVER IF NECESSARY) AND
INSTALL THE WASHERS IN SEAT.
Fig.1
Fig.2
Fig.3

6 MAN-071
-INSTALL THE 2 NUTS
(SEE FIG. 4)
TORQUE AT 9 ÷ 11 Nm (80 ÷ 100 in-lb)
“T” WRENCH 10 mm
3.2
PREPARATION AND INSTALLATION OF THE MOTOR-MOUNT
NOTE: ALL THE DIMENSIONS ARE IN MILLIMETERS
-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

7 MAN-071
3.3
ASSEMBLING THE CARBURETTOR
-INSTALL THE GAS CABLE CLAMP ON THE
SUPPORT
(SEE FIG. 6)
12 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

8 MAN-071
--INSTALL THE INTAKE SUPPORT
N°2 SCREWS M5x10
(SEE FIG. 10)
ALLEN WRENCH 3mm
3.4
INSTALL THE CARBURETTOR
REMOVE THE N°2 M6 NUTS
REMOVE THE PLASTIC CAP
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

9 MAN-071
3.5
INSTALL ENGINE ON THE CHASSIS
-POSITION THE ENGINE ON THE 2 MAIN RAILS
AND FIX THE MOTOR-MOUNT WITH THE TWO
CLAMPS
(SEE FIG.14)
SUGGESTION:
NEVER TORQUE COMPLETELY THE CLAMPS
UNTIL THE 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
(½÷¾ inch) MEASURED IN THE SHOWN POINT
(SEE FIG. 17)
-TORQUE THE CLAMP SCREWS
15mm
Fig.14
Fig.15
Fig.16
Fig.17

10 MAN-071
3.6
INSTALL THE CLUTCH COVER
-REMOVE THE 3 SCREWS M6x30 ON THE
CRANKCASE (SEE FIG. 18) AND INSTALL THE
CLUTCH COVER (SEE FIG.19).
TORQUE THE 3 SCREWS AT 8 ÷ 10 Nm
(70 ÷ 90 in-lb)
5 mm ALLEN WRENCH
3.7
ELECTRICAL CONNECTION
-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. 21
Fig. 20
Fig. 18

11 MAN-071
3.8
INSTALL THE INTAKE SILENCER
-MAKE SURE THAT THE INTAKE SILENCER
HAS THE INLET HOLE TOWARDS THE UPPERSIDE
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

12 MAN-071
4- GASOLINE AND OIL
Use leaded or unleaded gasoline with minimum 95 ROM, mixed with oil at 3% (33:1).
Use oils containing ricinoleate which ensures optimum lubrication at high temperatures
As on the other hand use oils containing ricinoleate creates gummy residues which give
origin to carbon deposits, 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 tube on the carburettor side. Make sure there is no air
in the tube.
Connect the tube to the carburettor.

13 MAN-071
5- CARBURETTOR ADJUSTMENT GUIDE
1 T.O.*
RICH LEAN
1 ¼T.O. ¾ T.O.
1 ½T.O.
*T.O. = TURNS OPEN
Normally the correct setting of the mixture screws is the following:
L (close the screw completely and then open): 1.00 T.O. for HL 334B and 1.00 T.O. for HL 394A.
H (adjust T.O from closed to approximately): ¾ T.O. for HL 334B and 1.00 T.O. for HL 394A.
Based on various factors as altitude, ambient temperature etc. it might be necessary to adjust the carburetor to
optimize the performance of the engine.
ATTENTION:
- Never lean too much as lean mixture will overheat engine and cause seizure.
- Do not force H or L closed. It may damage the precision machined orifice and make the carb
unserviceable.
- The screws adjustment must be performed with warm engine.
(H)
Adjust T.O. from closed to
approximately: ¾ T.O. for
HL 334B and 1.00 T.O. for
HL 394A
(L)
Adjust T.O. from closed to approximately
1 T.O
(I)
Close by further 1 ½ T.O
after contact with throttle
lever.
Start the engine and warm it. If R.P.M. too
high adjust Icounterclockwise 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.
Adjust c.c.w. fractionally for
rich idle.
Trigger accelerator.
Engine is now idling at max. attainable
R.P.M. or slightly lower on rich side
Adjust I counterclockwise until 2000 ÷ 2500
R.P.M. is reached
Recheck Lscrew for optimum setting
required
Adjust Huntil best possible free speed is
reached. Turn clockwise for higher R.P.M.
Counterclockwise for lower R.P.M.
Adjust Lslightly richer by
1/8 ÷ ¼ T.O.
Bad
acceleration
Return to idle and check acceleration for
quick response and smooth pick-up.
Good
acceleration
Engine is ready to operate
( I ) THROTTLE
SPEED SCREW
( L )LOW SPEED FUEL MIXTURE
( H ) HIGH SPEED FUEL MIXTURE
MIXTURE sscrew
MMMIXTURESCREW

14 MAN-071
6- STARTING AND STOPPING THE ENGINE
The engine is started by pulling the handle that uncoils the rope. The rope rotates the pulley that engages
the ignition flywheel connected to the crankshaft.
This action, made with the appropriate energy and eventually repeated if needed, starts the engine.
First of all, the switch located on the right side of the engine and mounted on the bracket attached to the
clutch cover, must be turned on the “ON” position. Following, grip the handle of the starter, slightly pull
the first stroke of the rope and then pull it firmly, exploiting the stroke provided by rope.
WARNING: do not pull the rope to stroke end to avoid recoiling problems.
As soon as the engine starts, gently drive the rope back to its position returning the handle in its seat.
In the event of several void starting attempts, check that fuel is arrived to the carburettor.
In the event that the engine can not be started, refer to Sect. 15 "Troubleshooting”.
The engine is stopped by simply turning the switch on the “OFF” position.
7- ENGINE BREAKING-IN
The breaking-in of the engine must be performed following a few fundamental rules:
Adjust the carburetion. Start with an adjustment on the rich 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 ¾ throttle opening.
Never keep the same RPM for a long time.
4. Increase the speed for 5 minutes, at max. speed on the twisty parts of the circuit
and making the engine rich at half straight (cover with the hand for an instant the
holes on the air filter, keeping the throttle wide open).
ATTENTION:
Once the break-in is over and the engine is cold, check the torque of the exhaust header nuts as,
during the break-in, the nuts tend to loosen (refer to the attached table).
8- INLET SILENCER
Make sure that the inlet hole on the filter is towards the upper side and that it is not plugged.
Make sure that the clamp on the carburetor is not loosen and the intake silencer is well fastened to the
chassis.
Once a while, clean the inside from oil deposits. If necessary remove the rubber intake silencer and clean
the interior silencer with gasoline or solvent.
ATTENTION:
In case of rain it is necessary to protect the vertical hole of Intake Silencer with the water
proof plastic cover, as otherwise water by entering the engine could damage the
internal components of engine.
When weather is good, remove the cover.

15 MAN-071
9- RECOMMENDATIONS ON THE EXHAUST SYSTEM
Always make sure that the springs are well hooked to the manifold and in place. In case
of breakage, replace the broken spring. Never race the kart without the 2 springs in
place, as otherwise the exhaust pipe could vibrate beyond control.
Every 10 15 hours, open the exhaust muffler end and make sure that the holes on the
rear cone are not plugged.
10-CENTRIFUGAL CLUTCH
The engine has a low maintenance dry centrifugal clutch steel on steel. The following
prescriptions, if carefully followed, will allow a long clutch life.
ATTENTION:
When starting the engine, make sure that the brake pedal is fully pressed to avoid
sudden accelerations.
Once the engine is started and 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 clutch.
If the kart first dragging speed exceeds 4000 RPMs.
Every time the clutch has overheated (presence of smoke or smell of burning).
Clutch rotor and internal part of clutch drum must always be clean and dry.
Please degrease carefully the working surface every time you reassemble the clutch.
Please pay attention when lubrificating the chain, no chain lube must enter the clutch.
To check the clutch, you must remove the clutch cover and the clutch drum.
Replace the clutch
If the body diameter is lower than 83.3mm.

16 MAN-071
11-INSTRUCTIONS FOR THE DISASSEMBLY / ASSEMBLY OF THE CLUTCH
ATTENTION:
The following operations must be performed by a skilled mechanic under the condition to
have available the dedicated tools shown on the text, otherwise it is necessary to apply
to an Authorized Service Center. Refer to the following drawing during the operations.
OPERATIONS
TOOLS
Clutch disassembly
1. Remove clutch cover (3 screws M6).
Allen wrench 5mm –T type.
2. Using the special tool S 1436/2 (or clutch wrench
CH 24) and hooking itself to the clutch body 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
6. Apply clutch puller on clutch and remove clutch from
the crankshaft, with 12 point wrench 19mm.
Clutch puller: P.N. B-55614-C
12 point wrench 19mm.
7. Remove key from shaft.
1
2
3
4
5
6
7
8
9
1 Drum nut 5 O-Ring 9 Clutch body
2 External washer 6 Internal Washer
3 Roller cage 7 Locking nut
4 Clutch drum + Sprocket 8 Cone safety washer

17 MAN-071
Before assembling the clutch, degrease with diluent the shaft taper, the conical hole on the
clutch body, the clutch drum.
Clutch reassembly
TOOLS
1. Insert key on shaft.
2. Install clutch body and cone safety washer on shaft.
3. Install the M16x1 nut using the clutch wrench.
ATTENTION: turn counterclockwise as nut has left
thread
Clutch wrench CH 24
Special tool S 1436/2
(torque at 65 ÷ 75 Nm - 575 ÷ 665 in-lb)
5. Install the 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 the crankshaft, install and tighten the
M10 nut.
Clutch wrench CH 24
Special tool S 1436/2.
12 Point wrench - 17 mm
(torque at 30 ÷ 40 Nm - 265 ÷ 350 in-lb)
3. Install the clutch cover (3 screws M6).
Allen 5mm.
(torque at 8÷10 Nm - 70 ÷ 90 in-lb)

18 MAN-071
12- SPARK-PLUG THERMAL DEGREE
The engine is supplied with a standard NGK BR9EG spark plug which represents agood
compromise between the needs of a good break-in and the racing needs in normal
conditions.
The colour of the various parts of the spark plug more exposed to the combustion flames
gives a good indication on the adequacy of the thermal degree and on the carburetion. It is
necessary though to understand which of the two parameters has to be changed and only
the experience tells how to identify the most proper thermal degree of a spark plug as lean
or rich mixtures can generate the same final look which can be also achieved with a hot or
cold spark plug.
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 lean mixtures.
A correct thermal degree shows:
Color of the insulator end from yellow grey to
dark brown for mixtures respectively lean or rich.
An excessively cold spark plug shows the
symptoms, listed aside.
ATTENTION:
Use a colder spark plug with hot climates.
Insultator end and electrodes covered with black
shady soot.
Ignition difficulties.
Note: a wet or oily electrode could also mean
an excessively rich mixture.
COMPARISON TABLE BASED ON
THE THERMAL DEGREE
HOT
COLD
NGK
BR8EG
BR9EG