IAME Parilla MINI SWIFT Overhauling Manual
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IAME Parilla MINI SWIFT Overhauling Manual

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

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Summary of Contents for IAME Parilla MINI SWIFT

  • Page 1 60cc BABY & MINI SWIFT - TaG ENGINE OVERHAULING MANUAL 12/10/05 MAN-045 ING...
  • Page 2 INDEX Page 1. - ENGINE DISASSEMBLY 2. - CRANKSHAFT ASSEMBLY / DISASSEMBLY 2.1- CRANKSHAFT DISASSEMBLY 2.2- CRANKSHAFT ASSEMBLY 3. - ENGINE ASSEMBLY 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...

  • Page 3: Engine Disassembly

    1 – ENGINE DISASSEMBLY OPERATION TOOLS REQUIRED INSERT TWO SCREWS M8X60 ON THE VICE ON BENCH (tool as per draw. S725/3) CRANKCASE TO POSITION MOTOR ON THE BENCH. REMOVE CLUTCH: Fig.1 -REMOVE CLUTCH COVER 3 SCREWS M6 (See Fig.1). (5mm ALLEN T TYPE) Fig.2 -REMOVE SPARKPLUG AND INSTALL SPECIAL PISTON FITTING SO THAT...
  • Page 4 - REMOVE PISTON FITTING AND USING Fig.4 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).
  • Page 5 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) Fig.8 -REMOVE ROTOR (see Fig.9). -REMOVE KEY FROM CRANKSHAFT SEAT. Fig.9 REMOVE STARTER GROUP Fig.10...
  • Page 6 Fig.12 Fig.13 -REMOVE THE COUNTERSHAFT SUPPORT COVER . 3 SCREWS M6X20 (see Fig.13). Fig.14 -EXTRACT THE COUNTERSHAFT FROM THE SUPPORT. (see Fig.14). REMOVE THE HEAD : Fig.15 -LOOSEN NUTS BY ½ TURN (CROSS PATTERN DISASSEMBLY) AND THEN REMOVE (see Fig.15). 4 NUTS M8 4 WASHERS (13mm SOCKET T- TYPE)
  • Page 7 REMOVE CYLINDER (see Fig.16). Fig.16 REMOVE CYLINDER GASKET. Fig.17 REMOVE CIRCLIPS FROM PISTON (see Fig.17) (SCREWDRIVER WITH ROUND EDGES) ATTENTION: DO NOT SCRATCH PISTON OR CIRCLIP SEATS. REMOVE PISTON PIN, PISTON AND Fig.18 ROLLER CAGE USING THE PISTON PIN PUNCH (see Fig.18). (PISTON PIN PUNCH: P.N.
  • Page 8 REMOVE THE PUMP FIXING SCREWS Fig.20 (see Fig.20). 2 SCREWS M6X45 1 NUT M6 (5mm ALLEN T TYPE) (6 POINT WRENCH - 10mm) Fig.21 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).

  • Page 9: Crankshaft Disassembly

    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.
  • Page 10 DISASSEMBLE THE CON-ROD WITH WASHERS. REPEAT THE OPERATIONS TO EXTRACT THE CRANKPIN FROM THE OTHER HALF CRANKSHAFT (see Fig.3). Fig.3 BEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE CHECK STATUS OF CON-ROD (TOP -CENTESIMAL MICROMETER (21/50) AND BOTTOM) . IF OVALIZATION EXCEEDS 0.01mm, -BORE GAUGE WITH CHECK RING Ø24 and Ø16 REPLACE CON-ROD.

  • Page 11: Crankshaft Assembly

    2.2 – CRANKSHAFT ASSEMBLY OPERATION TOOLS REQUIRED PLACE THE CRANKSHAFT ASSEMBLY - 5 MeT PRESS TOOL (P.N. 10110-C) UNDER THE PRESS, - CRANKSHAFT ASSEMBLY KIT: P.N. 10110-C VERTICALLY PLACE THE CRANKSHAFT HALF INTO THE ASSEMBLY TOOL. OIL CRANKPIN AND CRANKPIN HOLE ON CRANKSHAFT HALF.
  • Page 12 EXTRACT BUSH FROM CRANKPIN AND PUT TOOL IN HORIZONTAL POSITION (see Fig.4). Fig.4 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. Fig.5 PLACE SECOND CRANKSHAFT HALF IN THE SEAT OF THE COUNTERPLATE...
  • Page 13 OIL CRANKPIN AND CRANKPIN HOLE ON CRANKSHAFT HALF . PUT TOOL IN VERTICAL POSITION (see Fig.8). Fig.8 PROGRESSIVELY PRESS THE TWO CRANKSHAFT HALVES TOGETHER. OPEN THE TOOL. PUT IT IN HORIZONTAL POSITION AND EXTRACT THE CRANKSHAFT. CHECK AXIAL PLAY OF THE CONROD (see Fig.9).
  • Page 14 ROTATE CRANKSHAFT AND LOOK AT DEFLECTION OF GAUGE NEEDLES. DEFLECTION MUST BE, AFTER CENTERING MAX. 0.01mm (see drawing). ADJUST CENTERING WITH COPPER HAMMER, IF NECESSARY (see Fig.11). Fig.11 3 – ENGINE ASSEMBLING BEFORE REASSEMBLING, WASH ALL THE PARTS WITH KEROSENE OPERATION TOOLS REQUIRED CRANKCASE REASSEMBLY:...

  • Page 15: 5Mm Allen T Type

    -SPECIAL TOOL AS PER DRAW. S725/3 INSERT BALL-BEARINGS TO BE ON Fig.2 UPPER SIDE AND OIL WHEN ASSEMBLING . USE TOOL AS PER DRAWING S725/3 (see Fig.2/3). Fig.3 Fig.4 INSERT CRANKSHAFT AFTER OILING CRANKSHAFT SEAT IN CRANKCASE. CRANKSHAFT MUST BE IN SAME POSITION AS IN ORIGINAL INSTALLATION (see Fig.4).
  • Page 16 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).
  • Page 17 INSERT OIL SEALS . Fig.10 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 : Fig.11 CHECK STATUS OF THE ROLLER CAGE.
  • Page 18 PLACE CIRCLIP ON TOOL -SPECIAL TOOL: P.N. 10121 GREASE TOOL, TO KEEP CIRCLIP IN PLACE. (see Fig.14). INSERT CIRCLIP (see Fig.15). CHECK THAT CIRCLIPS ARE IN SEAT. Fig.14 Fig.15 INSTALL A NEW CYLINDER GASKET . INSTALL CYLINDER (see Fig.16). Fig.16 VISUAL CHECK.
  • Page 19 BEFORE ASSEMBLING THE CLUTCH , WASH WITH DILUENT THE SHAFT TAPER, THE CONNECTING HOLE ON THE CLUTCH BODY, THE CLUTCH DRUM AND STARTER RING . - 10mm SOCKET T TYPE INSTALL THE CLUTCH : INSTALL THE STARTER RING ON THE CLUTCH BODY BY MATCHING THE 3 HOLES AND THE DRAGGING PIN (3 SCREWS M6) .
  • Page 20 - CLUTCH WRENCH: P.N. 10270 INSTALL THE CLUTCH BODY FIXING - 24m ALLEN WRENCH NUT USING THE CLUTCH WRENCH Fig.21 (see Fig.21). TORQUE AT 40÷50 Nm ( 350÷440 in-lb). ATTENTION: TORQUE COUNTERCLOCKWISE AS NUT HAS LEFT THREAD. INSTALL THE INNER WASHER (see Fig.22).

  • Page 21: Piston Fitting : P.n

    INSTALL THE PISTON FITTING - PISTON FITTING: P.N. 10271 SO THAT THE SHAFT DOES NOT - 12 POINT WRENCH - 17mm ROTATE (see Fig.25) AND TORQUE THE M1O NUT ON THE DRUM. (M10 NUT) (see Fig.26). Fig.25 TORQUE AT 30÷40 Nm ( 265÷350 lb-in). Fig.26 REINSTALL CLUTCH COVER - 5mm ALLEN T TYPE...
  • Page 22 INSTALL THE IGNITION: -PISTON FITTING: P.N. 10271 INSTALL PISTON FITTING ON HEAD. Fig.28 INSERT KEY ON SHAFT (see Fig.28). -12 POINT WRENCH 13mm INSTALL IGNITION ROTOR ON SHAFT (WITH TIMING PLATE TOWARDS THE EXTERNAL) (see Fig.29). INSTALL SCREW AND NUT M10. TORQUE AT 20÷26 Nm (175 ÷...

  • Page 23: Screws M6X45 (See Fig

    - 5mm ALLEN T TYPE INSTALL THE STARTING ASSEMBLY: INSTALL STARTER COUNTERSHAFT IN THE STARTER SUPPORT (see Fig.32). Fig.32 INSTALL COUNTERSHAFT SUPPORT COVER. 3 SCREWS M6X20 (see Fig.33). Fig.33 INSTALL STARTER. OIL’ “OR” AND PRESS STARTER IN SEAT, MAKE SURE THAT GEARS ENGAGE.
  • Page 24 Fig.36 INSTALL FUEL PUMP (see Fig.36) 2 SCREWS M6X45 1 NUT M6. (5mm ALLEN T TYPE) (12 POINT WRENCH - 10mm) CONNECT PUMP INTAKE PRESSURE TO THE Fig.37 CRANKCASE FITTING (see Fig. 37). INSTALL THE CARB. AND SECURE IT TO THE FITTING, BY MEANS OF THE STEEL CLAMP Fig.38 (see Fig.
  • Page 25 MAN-045 ING...
  • Page 26 CROSS PATTERN LOCKING ORDER ON CRANKCASE MAN-045 ING...
  • Page 27 MAIN PRESCRIPTIONS CRANKSHAFT MATCHING THE PISTON - Bearing seat diameter on the new engine Replace when size is lower than 0.03mm vs. original. ATTENTION: Play beween piston and liner must be: 0.08mm. If play is higher than 0.10mm, replace MAX. ALLOWED OVALIZATION ON CONROD piston.
  • Page 28 MAN-045 ING...
  • Page 29 OVERHAUL TOOL LIST SPECIFIC TOOLS AVAILABLE AT IAME DESCRIPTION P.N. • PISTON FITTING 10271 • CLUTCH LOCKING WRENCH 10270 • CLUTCH DISASSEMBLY TOOL B-55614-C • PISTON PIN FITTING 10202 • CIRCLIP ASSEMBLY TOOL 10121 • CRANKSHAFT ASSEMBLY KIT 10110-c it includes:...
  • Page 30 P.N. A-120910 (not included in the supply). This battery charger, which has been expressly selected by IAME for its characteristics, operates at 220V, is easy to use, and, automatically switches off when the charging is over.
  • Page 31 Disegno S725/3 MAN-045 ING...

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