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- Parilla x30 125cc RL-TaG
- Assembly Instructions & User Manual
IAME Parilla x30 125cc RL-TaG Assembly Instructions & User Manual
Summary of Parilla x30 125cc RL-TaG
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Man-043/b assembly instructions & user manual 20/10/11.
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Man-043/b 0 i n d e x section 1 description of the “parilla x30 125cc rl - tag” engine 1.1. Main features 1.2. Characterisstics of the engine / operational limits 1.3. Contents of packing 1.4. Accessories 1.5. Motor identification number section 2 preparation & installation of the engine on the chas...
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Man-043/b 1 section 1 - description of the “parilla x30 125cc rl - tag” engine 1.1 main features the “parilla x30” has been expressly designed and tuned for powering the karts for hobby racing on closed tracks destined for this specific purpose. When designing this new engine, we have considered the...
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Man-043/b 2 1.2 characteristics of the engine – operational limits the characteristics of the engine are the following : • cycle : otto / 2 stroke • original cubic capacity: 123.67 cc (125cc max.) • original bore: 54.00 mm • max. Theoretical bore: 54.28 mm • stroke: 54.00 mm • lubrication : fuel / o...
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Man-043/b 3 1.3 contents of the packing each “parilla x30” engine is supplied with the accessories under shown: exhaust system quantity • flexible 1 • spring for flexible 3 • exhaust fiber strip 1 • exhaust manifold 1 • exhaust muffler 1 induction • tryton hobby 27-c carburettor – Ø26 1 • intake sil...
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Man-043/b 4 1.4 accessories exhaust system battery with support complete electric assembly clutch cover / h.T. Coil intake silencer tryton hobby carburetor radiator radiator support kit water hose kit complete pump assembly thermostat ngk spark plug starter brushes kit.
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Man-043/b 5 1.5 motor identification number the official motor identification number can be found stamped on the lower left part of the crankcase, next to the electric starter (see fig.). The number normally includes a letter followed by 4 digits (there can be exceptions in some special cases). Othe...
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Man-043/b 6 section 2 - preparation and installation of the engine on the chassis note: in case the engine is supplied already assembled on 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 sec...
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Man-043/b 7 2.2 install the water cooling system note: to install the water pump belts it is necessary to remove the rear axle. 1 reinstall the rear axle after having inserted two belts. Suggestion: install other two belts as spares and fix them with tape to the axle. 2 install the water pump (1 scr...
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Man-043/b 8 4 install the belts and tension (see fig. 4). Tighten the screw m8x45. Torque at 18÷22 nm (160 ÷190 in-lb) before installing the radiator preassemble the following components 5 insert the 4 rubber dampeners into the fixing holes on the radiator (see fig. 5). 6 - place the radiator suppor...
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Man-043/b 9 - complete insertion of the radiator support bracket in the rubber dampeners (see fig. 7 and 8). 7 fix the radiator support bracket inserting also the radiator fixing bracket (radiator cap side – n°1 screw m6x90 and n°1 screw m6x85 with nut). Install the “l” shape bracket on the lower ra...
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Man-043/b 10 8 place the radiator fixing clamp on the chassis side rail (brake side) (n°2 screws m6x25). Tighten the bolts by hand (see fig. 10). Place the radiator so that the hole on the radiator bracket and one of the upper holes on the bearing support box , match (n°1 screw m8) once you find the...
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Man-043/b 11 2.3 exhaust header assembly note: the engine is supplied with the exhaust gasket and nuts already inserted. When the shipment is made the internal parts of the engine are protected by a blind gasket. (see fig. 1). 2.3.1 remove the nuts and the exhaust cover. 2.3.2 make sure the exhaust ...
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Man-043/b 12 2.4.2 install the motor-mount, make sure to use the m8 allen screws, with a lenght such as to engage, in the crankcase, a threaded lenght of 16÷19mm (the screw must protrude from the plate for 16÷19mm ) (see fig. 3 and draw. Pag. 11) 4 allen screws m8–torque at 22÷24 nm (190 ÷ 210 in-lb...
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Man-043/b 13 2.6 install the engine on the chassis 2.6.1 position the engine on the two outside main rails and fix the motor- mount with two clamps (see fig. 6) suggestion: never torque completely the clamps until the chain is installed and properly aligned. 2.6.2 check the alignment of the engine s...
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Man-043/b 14 install the clutch cover with h.T. Coil 2.7 2.7.1 remove the 3 screws m6x25 on the crankcase (see fig.10) and install the clutch cover with h.T. Coil. (see fig.11). Torque the 3 screws at 8 ÷ 10 nm (70÷ 90 in-lb). Note: if an horizontal motor-mount is used check and see if there is suff...
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Man-043/b 15 2.8 electrical connections (refer to the attached electrical schematic). Note: for a correct installation follow the under shown instructions. 2.8.1 insert the battery strap in the battery support (see fig. 13). 2.8.2 place the battery support box in the front of the chassis (under the ...
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Man-043/b 16 2.8.5 –connect the terminal from the ignition with the 8 pole terminal on the harness see fig. 17). -connect the one way terminal from the electric starter with the one way terminal on the harness (see fig. 18). Attention: make sure that the fixing tongues are properly inserted to guara...
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Man-043/b 17 2.8.8 fix the ground cable to the electric starter by means of the m6x12 screw (already on the engine see fig. 21). Torque at 8 ÷ 10 nm (70 ÷90 in-lb) attention: this operation is extremely important as an uncertain grounding could damage the power-pack beyond repair. 5 mm allen 2.8.9 f...
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Man-043/b 18 2.8.11 cut the dual-lock fixing strap and attach it to the electronic box, the starter fuse, and the fuse holder (see fig.25). 2.8.12 connect the electronic box to the 20 pole terminal in the wiring harness (see fig. 26). -connect the starter relay to the 4 pole terminal in the wiring h...
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Man-043/b 19 2.8.14 connect the cable from the starting assembly with the 8 pole terminal in the wiring harness (see fig. 29). Attention: make sure that the fixing tongues are properly inserted to guarantee the best possible connection of the terminals . 2.8.15 attach the dual lock fixing strap (clo...
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Man-043/b 20 2.8.18 place the wiring harness battery terminals under the battery strp (see fig. 33). Suggestion: never connect the battery until you are ready to start the engine. Seal the battery terminals with plastic tape to avoid that eventual vibrations might disconnect the terminals. 2.8.19 sc...
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Man-043/b 21 2.10 install the exhaust note: see section 3.8 for the recommendations on the ideal exhaust lenght. 2.10.1 install the flexible (l= 65mm flexible completely closed –) and the exhaust header (see fig. 37) and fit the insulating sleeve on the flexible (see fig. 38). 2.10.2 insert the flex...
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Man-043/b 22 section 3 - use of the engine 3.1 charging of the oil in the gearbox attention: the engine is suplied without oil in the gear box. Before starting the engine fill the box with sae 30 oil. Starting the engine with a dry box will damage the gears beyond repair - charge of the gear box: pu...
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Man-043/b 23 3.3 carburetor adjustment guide 1 t.O. * rich lean 1 ¼ t.O. ¾ t.O. 1 ½ t.O. * t.O. = turns open normally the correct setting of the mixture screws, after engine run-in, is the following: l (close the screw completely and then open): 1 t.O. (1 turn) h (close the screw completely and ...
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Man-043/b 24 3.4 starting and stopping the engine starting is achieved by the starting key. This is a 3 position key: 1- stop (key can be removed) 2- key 3- run in stop position the battery is disconnected and the engine stop signal is sent to the electronic box. In key position the battery is conne...
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Man-043/b 25 3.5 engine break-in the break-in of the engine must be performed following a few fundamental rules: 1. 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 ...
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Man-043/b 26 3.8 exhaust system before every test, make sure that the flexible is not damaged. Replace if necessary. Attention: in case the flexible is damaged, metallic particles could be sucked in the engine and cause a seizure. Always make sure that the springs are well hooked and in place. In ca...
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Man-043/b 27 3.9 battery the battery (12 v – 9 ah) is sealed and without maintenance. In order to lenghten the battery life it is necessary though to follow a few recommendations: when the tension drops below 12.6v. It is necessary to recharge the battery. max. Allowed recharging current is 1.8a...
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Man-043/b 28 3.10 warnings on the electrical system we are here listing the main warnings on the electrical system. Please keep this in mind during the whole life of the engine. Attention: if these prescriptions are not followed the electrical system and the engine could be damaged beyond repair. No...
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Man-043/b 29 3.11 spark plug and thermal degree the engine is supplied with a standard ngk br10eg spark plug, which represents a good compromise between the needs of a good break-in and the racing needs in normal conditions. Use of different spark plugs is possible and, as a general information, we ...
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Man-043/b 30 3.12 choice of the best sprocket ratio the life of an engine depends on many factors but most of all, upon the speed at which the engine is operated. If an engine is normally operated at speed higher than what recommended by the manufacturer, the wears and stress of the various componen...
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Man-043/b 31 the following example should clarify the procedure for the optimization of the sprocket ratio. Assume to use the engine with z=10 teeth engine sprocket and that during the preliminary track tests a z= 77 teeth axle sprocket has been used. from table 1 with z=10 as engine sprocket and ...
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Man-043/b 32.
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Man-043/b 33 section 4 - basic maintenance 4.1 centrifugal clutch the engine has a low maintenance dry centrifugal clutch. The following prescriptions, if carefully followed, will allow a long clutch life. When starting the engine, make sure that the brake pedal is fully pressed to avoid sudden acce...
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Man-043/b 34 4.2 instructions for the disassembly/assembly of the clutch attention: the following operations can be performed by a skilled mechanic, under the conditions to have available the dedicated tools shown on the text, otherwise it is necessary to apply to an authorized service center. Refer...
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Man-043/b 35 before assembling the clutch, wash with diluent the shaft taper, the connecting hole on the clutch body, the clutch drum and the starter ring. Install clutch 1. Install the starter ring on the clutch body by matching the three holes and the dragging pin (3 screws m6). Attention: make su...
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Man-043/b 36 4.4 replacement of the starter brushes operations pictures 1. Disassemble the starter - unscrew n°2 screws m6x35 (see fig.1). (5mm allen wrench – t type) - remove starter (see fig.2). Note: on the engines manufactured after september ‘05, the starter can be removed without taking away t...
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Man-043/b 37 2. Opening the starter - remove the plastic clamp and unscrew the screw m4 fixing the input cable to the starter (see fig.3) (phillips screwdriver) - unscrew 3 screws m5 “c” (see fig.4) (phillips screwdriver) fig.1 fig.3 fig.4.
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Man-043/b 38 3. - remove drum from starter keeping rotor in its seat (be sure to hold the rotor on its toothed side to prevent brushes from falling out from their seat) (see fig.5) - remove rotor from starter head (see fig.6) attention: when extracting rotor, the brushes may spring out from their se...
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Man-043/b 39 - remove silicone from brushes with a screwdriver (see fig.9). - remove springs - making pressure externally on the tin plate terminal, remove brush. (see fig.10). - install new brush terminal inside (see fig.11). - place little rubber cap on the terminal - reinstall the plate and fixe ...
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Man-043/b 40 4. 5. Replacement of the brush “b” - unloose the screw m3 “g” (see fig.13) - extract the brush - fix the new brush with screw m3 (phillips screwdriver) closing the starter - insert the new brush spring "a" into its seat. - install the brush . - keep the brush in place by pressing toward...
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Man-043/b 41 6. - check that o-ring "h" is installed on the starter head. - insert starter drum on the head being careful to prevent rotor from rotating and to prevent the brushes from falling out of their seat (see fig. 17). - screw the 3 screws m5 (see fig.18). (phillips screwdriver) - check that ...
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Man-043/b 42 4.5 scheduled maintenance following some simple maintenance standards will allow the engine to perform more reliably and have a longer life. Schedule components actions and comments before using exhaust flexible check status exhaust spring check status insulating sleeve check status sil...
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Man-043/b 43 4.6 troubleshooting below are some common faults, their probable causes and suggested remedy. Faults probable causes remedy starter will not crank when turning the key to run position bad connections on starter cables check and tighten bad grounding check connections and tighten interru...
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Man-043/b 44 4.7 engine preservation when engine is to remain unoperative for a long period it must be preserved as follow: disconnect the battery and charge it periodically (see sect. 3.9). disconnect carburetor and clean it. seal with tape the engine inlet and exhaust. The external of the en...
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Man-043/b 45.