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IAME Parilla Reedster 125cc Overhauling Manual

Summary of Parilla Reedster 125cc

  • Page 1

    07/11/07 man-052 1 overhauling manual reedster 125cc versions: f1 - f2 - f3 - f4 21/01/2009.

  • Page 2: Index

    07/11/07 man-052 2 index page 1. - reedster 125cc engine disassembly 1 2. - crankshaft disassembly / assembly 13 2.1 - crankshaft disassembly 13 2.2 - crankshaft assembly 15 3. - reedster 125cc engine assembly 18 attachments - fastener torque table - cross pattern locking order on crankcase - main p...

  • Page 3

    Man-052 1 1 –reedster 125cc engine disassembly operations pictures 1. Discharging oil from gearbox - unscrew the m6 screw for discharging oil (see fig.1). (5mm allen wrench – t type) - tilt the engine to facilitate oil discharging and check that the gearbox breather is free and (see fig.2). 2. Fix t...

  • Page 4

    Man-052 2 4. Remove the ignition - remove stator unscrew n°3 m5x25 screws (see fig.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 sp...

  • Page 5

    Man-052 3 5. Disassemble gear cover - unloose n°2 screws m6 fixing the starter clamp. - unscrew n°7 allen head screws m6 (see fig.8). (5mm allen wrench – t type) - remove cover and washer (see fig.9). (with the help of a plastic mallet if necessary) attention: pay attention not to damage the oil sea...

  • Page 6

    Man-052 4 7. Remove clutch - disassemble the cluth cover unscrew n°3 screws m6x25 (see fig.12). (5mm allen wrench – t type) - disconnect the ground cable from crankcase unscrew m6x12 screw (see fig.13). (5mm allen wrench – t type) - remove starter countershaft cover unscrew n°3 screws m6x25 (see fig...

  • Page 7

    Man-052 5 - remove the m20 nut fixing the clutch body (see fig.16). (30mm socket wrench) attention: turn clockwise as nut has left thread - 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 wre...

  • Page 8

    Man-052 6 8. Remove water pump - remove pump cover unscrew n°4 screws m6x20 (see fig.20). (5mm allen 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.23). (8mm - socket wrench...

  • Page 9

    Man-052 7 9. Remove gears - remove the retainer ring on the countershaft (see fig.24). (pliers for retainer ring) - remove gear on the countershaft (use the puller p.N. Att-010 if necessary) - remove cone safety washer - unscrew nut on the crankshaft (see fig.25). (27mm socket wrench) - remove the g...

  • Page 10

    Man-052 8 - extract the bearing support by pushing counter crankshaft from the side of the water pump (see fig.28). Attention: pay 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 an...

  • Page 11

    Man-052 9 - remove valve cover and retaining 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.35). Fig.25 fig.32 fig.33 fig.34 fig.3...

  • Page 12

    Man-052 10 - detach the diaphragm from the exhaust valve body pulling it by hand (see fig.36). - disassemble the spring ring retaining the diaphragm and valve piston, also called " “head" and remove it. (see fig.37). - clean carefully the valve parts and remove the exhaust gas and oil residues (see ...

  • Page 13

    Man-052 11 14 . Remove cylinder - unscrew n°4 nuts m8 by half turn (cross pattern disassembly ) and remove them (see fig.40). (12mm socket wrench) - remove washers. - remove cylinder base gasket 15. Remove piston - remove piston pin circlips from piston (see fig.41). (screwdriver with rounded edge) ...

  • Page 14

    Man-052 12 - remove the crankshaft (see fig.44). - remove oil seals (use a screwdriver) (see fig.45). 17. Remove bearings (if 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 th...

  • Page 15

    Man-052 13 - remove the balance shaft internal bearing with the special tool after having removed the oil seal (att.011/3) (see fig.48). 2 – crankshaft disassembly / assembly attention: the assembly/disassembly operations on the engine crankshaft, must be performed only by an authorized service cent...

  • Page 16

    Man-052 14 3. Place the crankshaft insert (p.N. 10106) and using the crankpin pusher ( p.N. 10107 ) press the crankpin out (see fig.2). 4. Disassemble the complete con-rod with washers and cage. Repeat the operations to extract the crankpin from the other half crankshaft (see fig.3). Insert a crankp...

  • Page 17

    Man-052 15 2.2 – cranksahft assembly operations pictures 1. Place the crankshaft assembly tool (p.N. 10110b-c) under the press, vertically (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 cra...

  • Page 18

    Man-052 16 7. Extract crankpin bush, oil crankpin and install: -silver shim -con-rod with roller cage -silver shim (see fig.4). Attention: rollers are free in the cage. Prevent them from falling, when inserting the cage on the crankpin. 8. Place clamp jig in horizontal position and place half cranks...

  • Page 19

    Man-052 17 11. Oil crankpin and crankpin hole on half crankshaft. 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 crankshaft. 15. Check the axial play of the con-rod (see fig. 9). ...

  • Page 20

    Man-052 18 b. Rotate crankshaft and check deflection of gauge needles the deflection must be, after centering, max. 0.01mm (see drawing). C. Adjust alignment with a copper hammer, if necessary (see fig.11). 3 –reedster 125cc engine assembly before reassembling, wash all parts with kerosene operation...

  • Page 21

    Man-052 19 - insert crankshaft bearings; balls to be visible on upper side during assembly (see fig. 2). - oil outside of bearings and bearing seats , before assembly. Use special tool (att-011/1) to insert the bearings (see fig. 3) install the inner balance shaft bearing, balls to be on upper side ...

  • Page 22

    Man-052 20 2. Crankcase assembly - lubricate the crankshaft seats, ball bearings, big end cage before assembling (vedi fig.6). - also lubricate the inner balance shaft bearing. - install crankshaft the crankshaft must be in same position as in original installation (see fig.7). Attention: as first s...

  • Page 23

    Man-052 21 - insert crankshaft and close crankcase halves (see fig.10). - assemble crankcase halves n°9 screws m6 (see fig.11). (cross pattern locking – (see attac hed sketch) torque at 8÷10 nm (70 ÷ 90 lbf*in) (5mm allen wrench – t type) 3. Fitting oil seals - apply special lubricant on seal lips. ...

  • Page 24

    Man-052 22 - assemble bearing support and balance shaft (see fig.14). N°6 screws m6 torque at 8÷10 nm (70÷90 lbf*in) (5mm allen wrench – t type) lubricate the balance shaft external bearing - install water pump seal with the special tool (p.N. Att-016) (see fig.15). (mark on seal to be turned toward...

  • Page 25

    Man-052 23 note: if gears have not been replaced, reinstall them in their original position . ( identify the gear marked during the disassembling and assemble it on crankshaft). Install retaining ring on the balance shaft make sure that ring is in place at bottom of its slot (see fig.18). (pliers fo...

  • Page 26

    Man-052 24 7. Assembling the gear cover - place gasket on crankcase (see fig.21). - position cover by inserting starter end in its proper seat. (check that the vibration damping fitting is in place and oil it before inserting the starter). N°7 screws m6x16 (see fig.23). Torque at 8÷10 nm (70 ÷ 90 lb...

  • Page 27

    Man-052 25 9. Installing the piston - check status of the piston pin cage. It is recommended to replace it after 30 hrs and always when overhauling the engine. - check status of piston pin. Replace it when replacing piston. ( see attachment on matching selections between piston pin / cage). - instal...

  • Page 28

    Man-052 26 - iinsert circlips (see fig.30). Check circlips to be in seat. Attention: the circlip ends must be opposite to the piston extraction notch 10. Installing the cylinder - place a new gasket on the cylinder base. Oil cylinder liner and piston. Install cylinder (see fig.31). N°4 nuts m8 with ...

  • Page 29

    Man-052 27 12. Assembling the ignition and engine timing - insert key on shaft (see fig.34). - install rotor on shaft - install piston retainer (p.N. 10271) on head 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 (...

  • Page 30

    Man-052 28 - after having set to "0" the dial gauge rotate crankshaft in the opposite direction vs the direction of operation (clockwise, looking at the ignition): 2.3mm for f1 2.6mm forr f2 4.9mm for f3 4.1mm for f4 (see fig.38). - preventing the crankshaft from turning, rotate ignition stator unti...

  • Page 31

    Man-052 29 before assem bling the clutch, wash with diluent the shaft taper, the starter ring fixing hole, the clutch body and the clutch drum. 14. Installing the clutch - install starter ring on clutch body by matching the 3 holes and the dragging pin (see fig.42). - install n°3 screws m6x12 apply ...

  • Page 32

    Man-052 30 - install clutch drum, outer washer and m10 nut (see fig.46). Attention: install washer with bevel towards crankshaft - apply “loctite 243” on threads and tighten the m10 clutch drum retaini ng nut (see fig.47). Torque at 30÷40 nm (265 ÷350 lbf*in) (17mm socket wrench) - remove the starte...

  • Page 33

    Man-052 31 - install clutch cover n°3 m6x25 allen screws (see fig.50). Torque at 8÷10 nm (80 ÷100 lbf*in) (5mm allen wrench t type) 15. Instal the reed group - install internal gasket, reed valve, external washer and inlet duct, with pressure air intake hole towards upper side (see fig.51). Attentio...

  • Page 34

    Man-052 32 - install head on the diaphragm and insert the retaining spring with the special tool (see fig.54). - install gasket, spacer and o'ring, slide spindle and screw it in the "head" until contact but without forcing it (see fig.55). Attention check that the gasket pressure hole matches the on...

  • Page 35

    Man-052 33 - fix valve bodies n°2 screws m6 (see fig.58). Torque at 8÷10 nm (70 ÷90 lbf*in) proceed as follow:  screw in the m6 screws without torquing  check that valve is freely slipping torque screws at 4÷5 nm (35 ÷45 lbf*in)  check again valve slipping  torque definitely at 8÷10 nm (80 ÷100 ...

  • 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: Main Prescriptions

    Man-052 36 main prescriptions crankshaft - bearing seat diameter on new engine for halfcrankshaft wear, please refer to the attached table. Matching the piston attention: play between piston and liner must be 0.11÷0.12mm. If play is higher than 0.14mm replace piston piston to be measured at 18mm fro...

  • Page 39

    Man-052 37.

  • Page 40

    Man-052 38 overhaul tool list specific tools available at iame description p.N.  gear disassembly tool att-010  rotor disassembly tool att-009  piston fitting 10271  clutch disassembly tool 10272-c  piston pin fitting tool 10200 ? ?  crankshaft assembly kit it includes: - crankpin bush 10110b-...

  • Page 41

    Man-022 39 table for wear evaluation on bearings/ halfcrankshafts note: always check dimensions in different points on circumference, looking for eventual ovalizations on the following table are shown the ovalization limits above which replacement is required measured part (measuring instrument) lim...

  • Page 42

    Man-022 40 fixing engine tool on bench vice 40