REEDSTER 125cc
Contents
1. ET RPE TOY AE sss 7 a p r 523 541 5 60 5 97 6 15 6 33 652 6 70 688 7 07 ra 7 80 8 17 Max engine Sprocket ratio RPM during m 800 8 26 738 Tata 1685 mess 1021 703 EZ EE 7 1081 959 992 o ass ear sa sz 9 55 9 77 10 00 x 8 19 928 950 807 XJ s s ow 24 8 8 co tn ABE 8 18 sao ees Ce 8 JI 7 36 155 7 75 7788 8414 834 852 8 73 727 746 ras 023 862 36 MAN 051 ING Section 4 ENGINE BASIC MAINTENANCE 4 1 RECOMMENDATIONS ON 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 accelerations A ATTENTION Once the kart is started avoid useless accelerations which can overheat and deteriorate the clutch Oil the chain before each test When lubricating the chain avoid the oil penetration through the lightening holes of the drum Therefore do not spray oil close to the sprocket but inside the lower branch of the chain near the sprocket on the axle In case of lubricant penetration2. amm 1 j i w SC um with FETE pole teme nnesiar SELEM A rue feme rameh y pss male seg rem cuo Wing fori ath Connector I t 8 ne male coanectar EEFECOM Cananen he ihe H T sed ao fomai demm play WHA EFT PX holder with T4 use x Commer ta Femnic fastan like ALT cal 8 3 Cais Ey TE MN e dx H T ad s BATTERY ja MAN 051 ING 43
3. soe 824 8421 sso err sos e 7 77 144 5 17 535 552 570 587 605 622 6 40 657 6 75 6 93 7 10 728 745 7 63 780 511 5 28 580 5 97 6 14 E 6 49 6 66 6 84 E 7 18 7 36 E 7 70 ar 4 87 5 04 5 21 538 5 55 5 72 590 607 624 641 658 6 75 692 7 09 EI 7 43 760 4600 4 64 4 81 498 5 15 5 32 548 5 65 5 82 599 6 16 633 6 50 667 6 83 7 00 7 17 7 34 71 35 MAN 051 ING SPROCKET RATIO TO ACHIEVE MAX 14500 RPM F2 Tab 3 Max engine Sprocket ratio pes ona idi 2 il e Ter 534 835 855 1095 1027 os 1075 eam es 701 125 re ris sz ues von 950 ses 926 1010 bes 12800 5 23 6 46 8 58 E na 736 7 58 T82 8 04 827 8 50 8 72 8 95 9 18 8 40 983 8 86 6 70 692 7 14 T 35 7 53 fF E 3 12 334 IE 703 725 747 7 68 7 855 8 7 EXE 920 9 41 963 693 7 14 7 36 9 28 949 532 683 1673 694 7 18 735 Tat 777 T 860 6 80 kar 922 6 43 e 5 84 7 05 7 25 AE 7 88 8 07 827 x Sul 6 80 9 09 ao sos son soe sar ese are ese 155 os roa 124 vac sl asa ar sar tar ms ae at T
4. 10 The electric system is protected against the battery polarity reversal When reversing the connectors on the battery the protection circuit activates the fuse as soon as the key is in RUN o START position The fuse must then be replaced 11 Replace the fuse after having disconnected both terminals on the battery 12 13 14 15 16 Only use 5A strip fuse Use of fuses with higher amperage might damage the electronic box whenever the battery polarity is reversed Only use sealed lead type batteries as specified by IAME Only use 12V batteries Always disconnect the battery from the electrical system when recharging the battery with an external battery charger otherwise the internal voltage regulator could be damaged DO NOT connect batteries in parallel this might cause explosions and damages to the operator The recharge of the battery in normal conditions battery charged proper starting etc is guaranteed by the electrical system A few minutes of engine in operation is sufficient to recover the energy lost when starting the engine In case the battery must feed other users tachometer telemetry etc first contact IAME to check the recharge capacity of the system Modifications interventions and additions to the original electric system might cause malfunctions No obligation of IAME exists in this case 32 MAN 051 ING 3 12 SPARK PLUG AND THERMAL DEGREE The engine is supplied with a standard NG
5. IN THE ENGINE MOUNT NOTE PREFERABLY USE A FLAT MOTOR MOUNT M _ O13 5214 mi hm 2 s qe i MOTOR MOUNT HORIZONTAL VIEW 10 MAN 051 ING 2 4 2 INSTALL THE MOTOR MOUNT MAKE SURE TO USE M8 ALLEN SCREWS WITHA LENGTH SUCH AS TO ENGAGE IN THE CRANKCASE A THREADED LENGTH OF APPROX 16 19mm THE SCREWS MUST PROTRUDE FROM THE PLATE FOR APPROX 16 19mm SEE FIG 3 AND DRAWING PAGE 10 4 M8 ALLEN SCREWS TORQUE AT 22 24 Nm 190 210 in Ib 6 mm HEXAGONAL WRENCH K F1 F2 F3 VERSIONS THROTTLE CARB 2 5 1 REMOVE THE PLASTIC PLUG FROM THE INLET MANIFOLD A ATTENTON MAKE SURE THAT THE PRESSURE HOLE ON THE GASKET IS NOT PLUGGED 2 5 2 INSTALL THE CARBURETTOR N 2 NUTS M6 TORQUE AT A 6 10 Nm 50 90 in Ib SEE FIG 5 HEXAGONAL WRENCH 5 mm ATTENTION WHEN REPLACING THE CARB GASKET ALWAYS MAKE SURE THAT THE GASKET IS INSTALLED SO THAT THE PRESSURE HOLES ON THE INLET MANIFOLD AND ON THE INLET CARB ARE NOT PLUGGED AND MATCH OTHERWISE THE ENGINE WON T START NOTE WHEN USING CARBS PROVIDED WITH AN EXTERNAL PRESSURE INTAKE NOT ON THE FIXING FLANGE IT WILL BE NECESSARY TO REMOVE THE PLUGGING SCREW ON THE LEFT SIDE OF THE INLET DUCT SEE ARROW AND INSTALL THE PROPER MANIFOLD 11 MAN 051 ING F4 VERSION FLOAT CHAMBER CARB 2 5 3 INSTALLATION OF THE FUEL PUMP IF NOT ALREADY ASSEMBLED IN ORIGIN INSTALL THE VIBRATION DAMPENERS ON
6. REEDSTER 125cc F1 F2 F3 F4 Versions ASSEMBLY INSTRUCTIONS amp USER MANUAL 09 03 07 MAN 051 ING INDEX N Page Section 1 DESCRIPTION OF THE Parilla REEDSTER 125cc ENGINE 1 1 1 Main features 1 1 22 Engine characteristics operation limits 2 1 3 Contents of the packing 3 1 4 Accessories 4 1 5 Motor identification number 5 Section 2 PREPARATION amp INSTALLATION OF THE ENGINE ON THE CHASSIS 6 2 1 Installation sketch of the engine on the chassis 6 2 2 Install the water cooling system only F3 F4 versions 7 2 3 Preparation of the engine 10 2 4 Preparation and installation of the motor mount 10 2 5 Install of the carburettor 11 2 6 Charging the oil in the gear box 13 2 Installation of the engine on the chassis 14 2 8 Installation of the clutch cover with the H T coil 15 2 9 Electrical connections 16 2 10 Install the intake silencer 21 2 11 Install the exhaust 21 Section 3 USE OF THE ENGINE 22 3 1 Charging discharging oil in the gear box 22 3 2 Gasoline and oil 22 3 3 Carburettor adjustment guide 23 3 4 Starting and stoppping the engine 27 3 5 Engine break in 28 3 6 RPM limitation 28 3 7 Inlet silencer 28 3 8 Exhaust system 29 3 9 Exhaust valve adjustment guide only for F1 F2 F4 29 3 10 Battery 31 3 11 Warnings on the electrical system 32 3 12 Spark plug and thermal degree 33 3 13 Choice of the best sprocket ratio 34 Section 4 ENGINE BASIC MAINTENANCE 37 4
7. 22mm HOLE IN THE SIDE EDGE OF THE FRONT PANEL FAIRING ENGINE SIDE AND INSTALL THE STARTER ASSEMBLY SEE FIG 32 SECURE THE STARTER ASSEMBLY WITH THE THREADED LOCKING NUT 2 9 13 CONNECT THE STARTER ASSEMBLY CONNECTOR TO THE 8 POLES CONNECTOR ON THE HARNESS SEE FIG 33 A ATTENTION MAKE SURE THAT THE FIXING TONGUE OF THE CONNECTOR IS PROPERLY INSERTED TO GUARANTEE THE BEST POSSIBLE CONNECTION OF THE TERMINALS 2 9 14 ATTACH THE DUAL LOCK STRAP UNDER THE FAIRING CLOSE TO THE STEERING COLUMN AND INSTALL THE ELECTRONIC BOX AND THE STARTER RELAY SEE FIG 34 NOTE CLEAN AND DEGREASE THE SURFACE WHERE THE STRAP IS TO BE PLACED TO GUARANTEE THE BEST POSSIBLE ATTACHMENT FOR A BETTER FASTENING SECURE THE ELECTRONIC BOX RELAY WITH SCREWS BY USING THE EXPRESSLY MADE HOLES FOR THIS PURPOSE 19 MAN 051 ING 2 9 15 DRILL THE FAIRING AND FASTEN THE HARNESS WITH PLASTIC CLAMPS SEE FIG 35 2 9 16 DRILL THE FAIRING CLOSE TO THE BATTERY AND PLACE THE FUSE HOLDER BY MEANS OF THE 2 HOOKS OF THE JUNCTION BLOCK SEE FIG 36 THE HARNESS UNDER THE STRAP SEE FIG 37 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 9 18 SCREW THE SPARK CAP ON THE H T COIL CABLE SEE FIG 38 20 MAN 051 ING 2 9 19 FIX THE CAP TO THE H T CABLE WITH A PLASTIC
8. after engine run in F1 engine vers IBEA L7 30 carburettor H 1 10 1 turn and 10 L 1 30 1 turn and 30 F2 engine vers IBEA L6 24 carburettor 1 10 1 turn and 10 L 1 25 1 turn and 25 F3 engine vers TRYTON F3 20 carburettor H 0 20 20 L 1 30 1 turn and 30 Based on various factors as altitude ambient temperature etc it might be necessary to reset the carb setting to optimize the performance of the engine A ATTENTION A Never lean too much as lean mixture will overheat the engine and cause seizure Do not force H or L closed It may damage the precision machined orifice and render the carb inserviceable The adjustment of the screw must be performed with warm engine 23 MAN 051 ING F4 engine vers DELL ORTO VHSH30 CS CARBURETTOR SETTINGS AND CHARACTERISTICS At jN JET NEEDLE JET DP 254 HOLE JET 60 NEEDLE SEAT STARTER JET E THROTTLE VALVE EMULSION TUBE SEPARATE FLOATER X6 gr NEEDLE K29 3 notches The above settings are those prescribed by IAME for the carb Dell Orto VHSH 30 CS installed on the Parilla REEDSTER engine in the F4 version The above table shows the reference setting for the proper engine operation under different temperature altitude and atmospheric pressure conditions Should you need an optimized carb setting for all atmospheric conditions it will be necessary to adjust the setting for a better mixture
9. 051 ING COMPLETE INSERTION OF THE RADIATOR SUPPORT BRACKET IN THE RUBBER DAMPENERS SEE FIG 3 AND 4 FIX THE RADIATOR SUPPORT BRACKET INSERTING ALSO THE RADIATOR FIXING BRACKET RADIATOR CAP SIDE N SCREW M6x90 AND N SCREW M6x85 WITH NUT INSTALL THE Z SHAPE BRACKET ON THE RADIATOR SUPPORT BRACKET TONGUE 1 SCREW M8X45 WITH NUT DO NOT TIGHTEN THE SCREW SEE FIG 5 FIX THE RADIATOR Z SHAPE LOWER BRACKET ON THE CHASSIS RAIL FIXING BRAKE SIDE N 1 M8x65 SCREW DO NOT TIGHTEN THE SCREW SEE FIG 6 N B EVENTUALLY USE THE OUTFIT BUSHINGS TO ADJUST THE RADIATOR POSITION MAN 051 ING PLACE THE RADIATOR SO THAT THE HOLE ON THE RADIATOR FIXING BRACKET MATCHES WITH ONE OF THE UPPER HOLES ON THE BEARING SUPPORT BOX SEE FIG 7 ONCE YOU FIND THE CORRECT POSITION TIGHTEN THE M8x45 SCREW AND M8X65 ON THE LOWER Z SHAPE BRACKET THUS FIXING THE RADIATOR TIGHTEN AT 8410 Nm 70 90 in Ib THE KIT INCLUDES TWO RUBBER HOSES OF WHICH THE LONGEST ONE HAS TO BE CUT IN 4 DIFFERENT LENGTH HOSES SEE FIG 8 CONNECT THE 1 HOSE BETWEEN THE RADIATOR INLET AND THE THERMOSTAT OUTLET CONNECT THE 2 HOSE BETWEEN THE RADIATOR OUTLET AND THE T FITTING CONNECT THE 3 HOSE THE SHORTEST ONE IN THE KIT BETWEEN THE SMALLEST THERMOSTAT OUTLET AND THE T FITTING CONNECT THE 4 HOSE BETWEEN THE ENGINE INLET FITTING AND THE T FITTING CONNECT THE 5 H
10. CLAMP SEE FIG 39 e INSTALL THE SPARK PLUG TORQUE AT 20 26 Nm 175 230 in Ib e INSTALL THE CAP ON THE SPARK PLUG NOTE FOR A CORRECT DIGITAL IGNITION OPERATION THE CAP AND OR THE SPARK PLUG MUST BE OF THE RESISTIVE TYPE AND HAVE A RESISTIVITY OF 5 KQ MIN INSTALL THE INTAKE SILENCER MAKE SURE THAT THE FILTER HAS THE INLET HOLES TOWARDS THE UPPER SIDE SEE FIG 40 AND THAT THEY ARE NOT PLUGGED TIGHTEN THE CLAMP ON THE CARB AND FIX THE FILTER TO THE CHASSIS SIDE RAILS WITH A CRADDLE SHAPE SUPPORT SEE FIG 41 INSTALL THE EXHAUST NOTE SEE SECTION 3 8 FOR RECOMMENDATIONS ON THE EXHAUST INSTALL THE EXHAUST SILENCER ON THE ENGINE FITTING AND SECURE IT WITH THE 2 SPRINGS SEE FIG 42 FIX THE SILENCER ON THE CHASSIS GRADDLE SUPPORT 21 MAN 051 ING Section 3 USE OF THE ENGINE 3 1 CHARGING DISCHARGING THE OIL IN THE GEARBOX ATTENTION The engine is supplied without oil in the gearbox Before starting the engine fill the gearbox with EP100 motor oil Starting the engine with a d earbox will damage the gears beyond repair charging the gearbox Put the engine in horizontal position unscrew the oil plug n 1 on the picture and oil level plug n 2 on the picture fill with oil until it comes out from the oil level plug approx oil quantity in the gearbox 33 Cc Exclusively use IAME EP100 motor oil check the oil level The oil level ca
11. TUBES M6x25 SCREWS SEE FIG 20 TORQUE AT 8 10 Nm 70 90 in Lb PIPE WRENCH 10mm THE SUPPORT BOX MUST BE FIXED WITH AT LEAST ONE BOLT FOR EACH CLAMP FIX THE BOX WITH MORE THAN ONE BOLT DEPENDING ON THE TYPE OF CHASSIS NOTE THE BOX AND CLAMPS ARE PROVIDED WITH VARIOUS HOLES TO ALLOW INSTALLATION ON ALL KIND OF CHASSIS 2 9 3 INSERT THE BATTERY IN THE BOX AND FASTEN IT WITH THE BATTERY STRAP SEE FIG 21 POSITION THE BATTERY TERMINALS AS SHOWN ON THE FIGURE AD ATTENTION PAY ATTENTION NOT TO SHORT CIRCUIT THE BATTERY TERMINALS AS THE BATTERY COULD BE DAMAGED BEYOND REPAIR 2 9 4 PLACE THE WIRING HARNESS STARTING FROM THE ENGINE ALONG THE RAILS THE STEERING COLUMN AND UNDER THE FRONT PANEL FAIRING SEE FIG 22 TIGHTEN WITH PLASTIC CLAMPS A ATTENTION NEVER LET THE HARNESS GET IN TOUCH WITH THE GROUND OR WITH ROTATING PARTS AS IT COULD BE DAMAGED BEYOND REPAIR 16 MAN 051 ING 2 9 5 CONNECT THE TERMINAL FROM THE IGNITION WITH THE 8 POLES TERMINAL ON THE HARNESS SEE FIG 23 CONNECT THE ONE WAY TERMINAL FROM THE ELECTRIC STARTER WITH THE ONE WAY TERMINAL ON THE HARNESS SEE FIG 24 fT 5 ATTENTION MAKE SURE THAT THE FIXING TONGUES ARE PROPERLY INSERTED TO GUARANTEE THE BEST POSSIBLE CONNECTION OF THE TERMINALS 2 9 6 CHECK THAT THE PLASTIC CLAMP FASTENS THE CABLE FROM THE ELECTRIC STARTER TO THE STARTER BODY SEE FIG 25 Jh X ATTENTION THIS OPERATI
12. and make sure that the holes on the internal counter cone are not plugged The equipment muffler has already been tuned to achieve the best possible performance Having fixed a sprocket ratio it could be necessary to improve the engine performance either at low or at high RPM This could be achieved by modifying the suggested exhaust length removing or adding the spacers placed behind the exhaust header In general by shortening the total length an improvement at high RPM is achieved and vice versa by lengthening it the low RPM is improved When testing though never exceed in lengthening or shortening by more than 5mm per time EXHAUST VALVE ADJUSTMENT GUIDE ONLY F1 F2 F4 The engine is provided with a pneumatic power valve on the exhaust duct to improve the performance at low RPM The power valve can be adjusted by turning the ring nut or by replacing the retaining spring inside the power valve The basic setting varies according to the spring type and is achieved by turning clockwise the ring nut until limit stop and then unscrewing and counting the number of notches necessary until you get an optimal setting 0 9mm L 45mm spring wire from the limit stop unscrew the ring nut by 2 notches all versions O 1mm L 43mm spring wire from the limit stop unscrew the ring nut by 15 notches all versions 29 MAN 051 ING 0 9mm L 45mm 2 NOTCHES 1mm L 43mm 15 NOTCHES NOTE ON THE PNEUMATIC POWER VA
13. clutch The engine is provided with a dry centrifugal clutch with low maintenance and with interchangeable sprocket 1 MAN 051 ING The battery 12 V 7 2Ah is a sealed no maintenance battery and is supplied already pre assembled in a support box which can be easily adapted to all existing chassis Both a throttle carburettor and a float chamber carburettor on the F4 version can be fitted on the engine In this last case the engine is provided with a fuel pump A power valve is fitted on the cylinder exhaust duct with the exception of the KF3 version to optimize the low range performance he exhaust system included in the supply is already tuned and optimized to guarantee the best efficiency The water pump is integrated in the engine and the water cooling system involves both the thermic group and the crankcase The engine only F3 and F4 is supplied with a kit which includes the homologated radiator the water hoses the thermostat and the fixing supports on the chassis 1 2 CHARACTERISTICS OF THE ENGINE OPERATION LIMITS The characteristics of the engine are the following Operational limits e Max RPM e Cycle OTTO 2 stroke e Original cubic capacity 124 08 cc 125cc max e Original bore 53 89 mm e Max theoretical bore 54 04 mm e Stroke 54 40 mm e Lubrification Fuel oil mix 4 25 1 e Induction Reed valve in the crankcase e Carburettor Diaphragm or float chamber only F4 e Cooling Wa
14. teeth sprockets are available as accessories Table 1 shows the various ratios between the sprocket on the axle and the engine sprocket given the different axle and engine sprockets Tab 1 Sprocket Sprocket ratio ratio Teeth n Teeth n axle 11 13 axle 11 12 13 sprocket sprocket Teeth n engine sprocket Teeth n engine sprocket 12 ma 655 6 554 755 5 61 87 791 725 669 78 70 65 6 s 80 742 685 90 818 75 692 80 727 667 615 To achieve the max RPM speed of 13500 RPM the table N 2 has been prepared To achieve the max RPM speed of 14500 RPM the table N 3 has been prepared To achieve the max RPM speed of 15500 RPM the table N 4 has been prepared 75 682 625 577 782 747 681 SUGGESTION During the track tests we recommend use of a tachometer recording the max obtained engine RPM Use spark plug caps or spark plugs with a min resistance of to avoid eventual interferences between the engine ignition and the tachometer and or telemetry 34 MAN 051 ING The following example should clarify the procedure for optimization of sprocket ratio assume to use an engine in the F4 version with a Z 12 sprocket and that during the preliminary track tests a Z 78 teeth axle sprocket has been used From the table 1 with Z 12 as engine sprocket and Z 8 on the axle sprocket a ratio of 6 5 is found Make a few laps on the track and
15. the starter ring on the clutch body by matching 12 point wrench 10 mm the three holes and the dragging pin 3 screws TE Torque at 10 Nm 90 in Ib 4 M6 apply Loctite on the threads ATTENTION make sure to always install the 7 mm dragging pin as otherwise the eventual kick backs could break the screws 2 Install the clutch body and the starter ring Apply Loctite 641 for coaxial lockings 3 Install the clutch body fixing nut and starter ring using Locking tool P N S884 the clutch wrench Allen wrench 30 mm torque at 100 120 Nm ATTENTION turn counterclockwise as nut has left thread 4 Installinner washer N ATTENTION install washer with bevel towards the crankshaft Clean the roller cage and grease it before installing it on the crankshaft 5 Install the clutch drum and the external washer ATTENTION install washer with bevel towards the crankshaft 6 Install the piston fitting to prevent the shaft from turning and install the clutch cover M10x1 nut Piston fitting P N 10271 17mm socket torque at 30 40 Nm 265 360 in Ib Allen wrench 5 mm T type torque at 8 10 Nm 70 90 in lb T Install the clutch cover 3 screws M 6 4 3 GEAR TIMING SCHEMATIC In case of assembly of the gears which drive the balance shaft assembly must be performed following the timing schematic shown below AN ATTENTION An incorrect assembly of the gears can ca
16. 1 Recommendations on the centrifugal clutch 37 4 2 Clutch assembly disassembly 38 4 3 Gear timing schematic 39 4 4 Scheduled maintenance 40 4 5 Troubleshooting 41 4 6 Engine and accessories preservation 42 4 7 Fastener torque table 42 Wiring diagram 43 MAN 051 ING Section 1 DESCRIPTION OF THE Parilla REEDSTER 125cc ENGINE 1 1 MAIN FEATURES The Parilla Reedster engine is the result of the decennial racing experience of IAME and It contains many technological and construction innovations which enable the engine to achieve both high performance and guarantee excellent reliability and endurance characteristics This engine has been designed and tuned for powering the karts for both hobby and agonistic racing on closed tracks destined for this specific purposes When designing the engine we have considered the technical solutions already adopted for the high performance engines and the experience acquired with the TaG series engines Touch and Go The Reedster engine has been homologated in 2006 according to the CIK FIA international rules and it is available in 4 versions F1 F2 F3 ed F4 This engine is a 2 stroke single cylinder The thermic group and crankcase are in aluminium alloy The pressed in liner is made of centrifuged cast iron and machined from the full to guarantee the best possible stability sliding homogeneity and precision The head is secured by 5 screws to the cylinder which is fitted to the c
17. ACCESSORIES PRESERVATION When engine is to remain out of operation for a long period it must be preserved as follows Disconnect battery and recharge it periodically see sect 3 10 Disconnect carburettor and clean it Seal with tape the engine inlet and exhaust The external of the engine must be cleaned Spray with protective oil the steel parts subject to oxidation Keep the engine in a dry ambient 4 7 TORQUE VALUES FASTENER NAME Hex 12 mexi 4 East not mens 10 70 90 M5 x 0 8 3 ignition stator fixing screw Allen 4 5 6 45 50_ MIZ 1 lin rotor nut Hox 17120 26 75 230 S rte set 4 4 ie 3 i 39 Allen 5 6 8 50 70 Clutch drum pecking nut 7 Starter ring and clutch fix nut Hex 30 Engine sprocket fixing screw Alen 3 amp 8 50 70 Hex 10 9 Crankcose fixing screw Allen 5 10 12 90 105 7 Gears cover fixing screw Allen 5 22 90 get supp fix screw Allen z coi ting mi 10 70 90 wear 5 colle bor gru ues 10 70 80 M8 x 1 2 Oil lev plug bal shaft insp Allen 4 12 15 105 130 Lus 1 2 nae mantots 7 oi arain ex 11 2 15 05 120 MIB x 1 1 Crankshaft gear fixing nut Hex 27 50 55 440 480 um eS LN Alien 3 Allen 5_ 5 l 5 laien 5 8 10 70 90 Hex 8 70 80 42 MAN 051 ING
18. K BR10EG 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 are attaching a correspondence list among spare plugs of other brands based on thermal deqree which represents the capacity of the spark plug to dissipate the Internal heat 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 also be achieved with a hot or cold spark plug See table An excessive warm spark plug shows the Extremely clear colour porous look and symptoms listed aside calcification of the electrodes and of the internal insulation ATTENTION Irregularities in the ignition pre ignition and Always use a warmer than standard spark plug detonation with tendency to perforate the top of with cold or rainy climate the piston Note some of these symptoms can achieved with lean mixtures A correct thermal degree shows Colour of the insulator end from yellow grey to dark brown for mixtures respectively lean or rich An excessively cold spark plug shows the Insulat
19. LVE OPERATION The power valve chokes the exhaust port opening at low RPM and achieves a more limited port timing diagram and a reduced exhaust port The power valve function is to optimize the engine performance up to a given RPM Above this RPM the power valve will open to re establish the original port timing in the mid top RPM range For the REEDSTER engine the opening RPM is set at approx 9500 RPM In addition to the above we can give a few recommendations to the driver for the proper adjustment of the power valve In any case such a procedure can also be followed to for the best opening RPM setting e Ifthe power valve opens too soon that is below 9500 RPM the driver will feel a power output discontinuity just under this speed limit In this case screw clockwise the adjustment ring nut on the power valve one notch at a time until the phenomenon disappears e the power valve opens too late that is over 9500 RPM the driver will feel a power output discontinuity above this speed In this case unscrew ccw the adjustment ring nut on the power valve one notch at a time until the phenomenon disappears The adjustment of the opening speed must be performed when the engine is warm and working at standard operation temperature When the engine is cold as it normally happens between two working sessions the oil residuals which are present between the exhaust valve and its seat reach a higher viscosity and this prevents th
20. ON IS VERY IMPORTANT OTHERWISE THE RESIDUAL ENGINE VIBRATIONS COULD DAMAGE THE ELECTRIC STARTER INNER CONNECTIONS BEYOND REPAIR 2 9 7 FASTEN THE 2 TERMINALS GROUND CABLES WITH EYELET TO THE H T COIL WITH THE M6 FIXING NUT SEE FIG 26 TORQUE AT 8 10 Nm 70 90 in Ib PIPE WRENCH 10mm An X ATTENTION THIS OPERATION IS EXTREMELY IMPORTANT AS AN UNCERTAIN GROUNDING COULD DAMAGE THE ELECTRONIC BOX BEYOND REPAIR 17 MAN 051 ING 2 9 8 CONNECT THE H T COIL CABLE TO THE HARNESS TERMINAL SEE FIG 27 A ATTENTION FASTEN THE CABLE WITH A PLASTIC CLAMP TO AVOID THAT EVENTUAL VIBRATIONS MIGHT DISCONNECT THE TERMINALS SEE FIG 28 2 9 9 CUT THE DUAL LOCK FIXING STRAP AND ATTACH IT TO THE REAR OF THE ELECTRONIC BOX THE STARTER FUSE AND THE RELAY SEE FIG 29 NOTE THE COLOUR OF THE ELECTRONIC BOX CHANGES ACCORDING TO THE ENGINE VERSION AND TO THE REV LIMITER SETTING YELLOW F4 vers 14000 RPM max BLUE vers 14000 RPM max GREEN F2 vers 15000 RPM max RED F1 vers 16000 RPM max 2 9 10 CONNECT THE ELECTRONIC BOX TO THE 20 POLE CONNECTOR ON THE HARNESS SEE FIG 30 A ATTENTON MAKE SURE THAT THE FIXING TONGUES ARE PROPERLY INSERTED TO GUARANTEE THE BEST POSSIBLE CONNECTION OF THE TERMINALS ELECTRONIC BOX 18 MAN 051 ING 2 9 11 CONNECT THE STARTER RELAY TO THE 4 POLES CONNECTOR ON THE HARNESS SEE FIG 31 2 9 12 DRILL A
21. OSE BETWEEN THE ENGINE OUTLET AND THE THERMOSTAT INLET FASTEN WITH STEEL CLAMPS ALL THE HOSE ENDS THE THERMOSTAT MUST BE POSITIONED SO THAT THE REAR UNION FOR THE RECYCLING COOL WATER IS PROPERLY FIXED TO THE T FITTING ON THE HOSE CONNECTING THE RADIATOR OUTLET TO THE ENGINE INLET FITTING SEE FIG 9 BEFORE STARTING THE ENGINE FOLLOW THESE RECOMMENDATIONS Unscrew the cap on the radiator and loosen the breather plug on the engine head Fill the radiator until the water comes out from the plug there is no air in the system now and the radiator is completely filled Tighten the cap the system contains approx 2 lt of water It is advisable to put a small cup to recover water from the breather on the radiator cap to avoid fluid leakages on the track After the engine run in check the water level in the radiator and top up if necessary 9 MAN 051 ING INITIAL PREPARATION OF THE ENGINE 2 3 1 ON THE EXHAUST POWER VALVE THERE IS A WARNING TAG TO REMIND THE USER THAT THE GEAR BOX MUST BE FILLED WITH OIL BEFORE STARTING THE ENGINE SEE FIG 1 NOTE THE ENGINE IS SUPPLIED WITH THE EXHAUST FITTING AND SPACER ALREADY PRE INSTALLED 2 3 2 WHEN THE SHIPMENT IS MADE THE ENGINE INNER PARTS ARE PROTECTED BY PLASTIC PLUGS WHICH MUST BE REMOVED BEFORE INSTALLING THE ENGINE SEE FIG 2 SPARK PLUG HOLE PLUG WATER FITTING PLUGS EXHAUST FITTING PLUG CARBURETTOR FITTING PLUG 2 4 1 DRILL 4 HOLES 8 25 8 5mm DIAM
22. PROCKET WITH A STRAIGHT EDGE SEE FIG 14 2 7 3 INSTALL THE CHAIN PITCH 7 775 SEE FIG 15 2 7 4 MOVE THE ENGINE ON THE RAILS AND OPTIMIZE THE CHAIN TENSION A ATTENTION THE CHAIN PLAY MUST BE OF APPROX 15mm MEASURED IN THE SHOWN POINT SEE FIG 16 2 7 5 TIGHTEN THE CLAMP SCREWS HEXAGONAL WRENCH 8mm MAN 051 ING INSTALLATION OF THE CLUTCH COVER WITH H T COIL 2 8 1 CONNECT THE H T COIL GROUND CABLE TO THE CRANKCASE BY MEANS OF THE M6 SCREW ON THE FRONT FOOT SEE FIG 17 TORQUE AT 8 10 Nm 70 90 in Ib HEXAGONAL WRENCH 5 mm A ATTENTION MAKE SURE THAT THE COPPER GROUND CABLE ALWAYS CONNECTS THE H T COIL WITH THE ENGINE AN INADEQUATE GROUNDING COULD DAMAGE THE IGNITION SYSTEM BEYOND REPAIR THE POSITION OF THE H T COIL HAS BEEN CHOSEN TO BE AS FAR AS POSSIBLE FROM THE EXHAUST AS THE EXCESSIVE HEAT COULD DAMAGE THE H T COIL BEYOND REPAIR 2 8 2 INSTALL THE CLUTCH COVER WITH H T COIL SEE FIG 18 TORQUE THE 3 SCREWS M6 AT 8 10 Nm 70 90 Ib HEXAGONAL WRENCH 5 mm 15 MAN 051 ING ELECTRICAL CONNECTIONS refer to the attached electrical schematic NOTE For a correct installation follow the under shown instructions 2 9 1 INSERT THE BATTERY STRAP IN THE BATTERY SUPPORT BOX SEE FIG 19 2 9 2 PLACE THE BATTERY SUPPORT BOX IN THE FRONT OF THE CHASSIS UNDER THE FRONT PANEL FAIRING AND FIX IT WITH THE CLAMPS TO THE LOWER STEERING COLUMN SUPPORT
23. THE GEAR BOX COVER SEE FIG 6 PLACE THE FUEL PUMP WITH THE OUTLET FITTING TOWARDS THE UPPER SIDE AND TORQUE THE SELF LOCKING NUTS M6 TORQUE AT 6 10 Nm 50 90 in Ib SEE FIG 7 10mm PIPE WRENCH 2 5 4 INSTALLATION OF THE CARBURETTOR REMOVE THE PLASTIC PLUG FROM THE INLET MANIFOLD AND INSTALL THE CARB THEN TIGHTEN THE STEEL CLAMP SEE FIG 8 CONNECT BY MEANS OF A TUBE FUEL PIPE TYPE THE PRESSURE INTAKE FITTING ON THE CRANKCASE AND THE PUMP PRESSURE INTAKE BY MEANS OF ANOTHER TUBE CONNECT THE FUEL PUMP OUTLET TO THE CARB MANIFOLD SEE FIG 9 12 MAN 051 ING CHARGING THE OIL IN THE GEAR 2 6 1 REMOVE THE OIL BREATHER PLUG REAR PART OF THE ENGINE SEE FIG 10 12 POINT WRENCH 11mm REMOVE THE OIL LEVEL PLUG FRONT PART OF THE ENGINE SEE FIG 11 L HEXAGONAL WRENCH 4mm 2 6 2 FILL WITH 33cc IAME EP100 OIL THE GEAR BOX SEE FIG 12 NOTE IF THE LEVEL IS CORRECT YOU WILL SEE A LIGHT OUTCOME OF OIL FROM THE OIL LEVEL PLUG INSTALL THE OIL LEVEL PLUG TORQUE AT A 12 15 Nm INSTALL THE OIL BREATHER FITTING TORQUE AT 12 15 Nm 13 MAN 051 ING INSTALLATION OF THE ENGINE ON THE CHASSIS 2 7 1 PLACE THE ENGINE ON THE TWO SIDE RAILS AND SECURE THE MOTOR MOUNT WITH THE TWO CLAMPS SEE FIG 13 SUGGESTION DO NOT TIGHTEN THOROUGHLY THE CLAMPS UNTIL THE CHAIN IS NOT INSTALLED AND PROPERLY ALIGNED 27 2 CHECK THE ALIGNMENT OF THE ENGINE SPROCKET AND THE AXLE S
24. UTCH A ATTENTION the following operations can 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 8 4 ke Cy ae UY v m fi 1 Drum nut 9 Clutch body 2 External washer 6 Clutch drum 10 Starter ring 3 Roller cage 7 Internal washer 11 Screw 4 Sprocket 8 Locking nut OPERATIONS TOOLS CR w Remove the clutch cover 3 screws M6 Allen Wrench 5mm T type 2 Remove the spark plug and replace with special tool Piston fitting P N 10271 to prevent crankshaft from turning 3 Remove nut 1 screw M10x1 12 point wrench 17mm 4 Remove the external washer the drum complete with roller cage the internal washer 5 Remove the special tool from the head and using the Clutch wrench P N 5884 clutch wrench remove the 20x1 nut and the starter 30mm socket ring TTENTION turn clockwise as the nut has the left thread Clutch puller P N 10272 C 6 Apply the clutch puller on clutch and remove the 12 point wrench 19mm clutch with starter ring 7 Remove the starter ring 3 screws M6 12 point wrench 10 mm 38 MAN 051 ING Before assembling the clutch wash with diluent the shaft taper the connecting hole on the clutch body the clutch drum and the starter ring 1 Install
25. e float chamber will increase and the exceeding fuel is discharged through the carb breather In this case it is necessary to disassemble the chamber remove the floaters and the admission valve then clean with compressed air see fig 6 7 e Incase of puncture of one or both floaters the admission valve cannot be closed and so the exceeding fuel overflows through the breathers In this case it is necessary to disassemble the float chamber check the fuel feeding into the floaters and replace them with others with same weight In case the engine has to remain out of operation for a long period the fuel admission valve could get stuck either on opening or on closing position due to presence of incrustations In the first case the same fuel overflowing phenomenon from the carb breathers is experienced in the second the engine does not start for insufficient feeding It is therefore necessary to disassemble the float chamber check if there is fuel inside remove incrustations and re establish the proper fuel admission through the floater valve assembly Fig 26 MAN 051 ING 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 RUN 3 START STOP RUN START N f S L ke n jogs W A f 1 J AE Ph mr E JU In STOP position the battery is disconnected and the engine stop signa
26. e pole positive terminal after Always disconnect the battery in opposite order Recharge the battery at least once every 6 months u Never put the battery in contact with solvents oils plastics or rags containing such elements as they may damage the external case Never press or bend or overheat by welding the battery terminals Other recommendations u Pay attention not to have free fires upon or around the battery u Never short circuit the terminals Never open the battery or throw it in the fire case the electrolyte diluted with Sulphuric Acid gets in contact with skin or clothes wash immediately with water In case it gets in touch with eyes wash and apply for medical assistance Carefully check the external case of battery and replace in case of breakages swellings of the case or of battery cover u Before use clean the battery from dust and check that the terminals are not oxidized or damaged When the battery comes to an end never throw it in the garbage but deliver it to an authorized disposer 31 MAN 051 ING 3 11 WARNINGS ON THE ELECTRICAL SYSTEM We are listing the main warnings on the electrical system Please keep this 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 obligation of IAME exists in this case 1 9 Please turn the key to STOP positio
27. e valve operation and delays its opening This situation can be experienced when the engine has not reached its operating temperature and this situation can be corrected by slightly unscrewing the adjustment ring nut We suggest though not to modify the setting as once the engine reaches the proper working temperature the oil becomes more fluid and the valve starts working again properly no other intervention is required 30 MAN 051 ING 3 10 BATTERY The battery 12 V 7 2 Ah is sealed and without maintenance In order to lengthen the battery life it is necessary though to follow a few recommendations u When the tension drops below 12 6V it is necessary to recharge the battery Max allowed recharging current is 1 8A u The ideal recharge is achieved with an average current of 0 8 1 A recharging time approx 10 hrs at an ambient temperature between 0 and 40 C ATTENTION An overcharge or an extremely quick charge with excessive current could damage the battery the battery would tend to swell Choose a battery charger with the following characteristics Feed tension 90 250 Vac 50 60 Hz Outlet tension 15 V full charge 13 8 stand by Max outlet tension 2A full charge u During transportation and or storage the battery could loose its charge due to self discharge 0 1 max per day Fully recharge battery before use A ATTENTION Always connect the negative terminal before and th
28. ease 25 MAN 051 ING On the contrary by increasing the altitude it is necessary to reduce the max jet size by about 2 3 points for every 350m altitude Increase The above data are only indicative as many factors influence the carburetion and only a few among them are ponderable With these indications we wish to give the owner a general guide line and avoid damaging the engine under variations of ambient conditions which make the carburetion substantially leaner A fine carb adjustment will always have to be made according to the experience and to the tests performed on the track As completion of this guide line here are a few general recommendations the carburettor is provided with an enrichment system for starting the engine C lever see fig 5 when the engine is cold and or when the engine has been kept out of operation for a certain time To get the max efficiency this device must be used with gas throttle closed or slightly a opened A few seconds after the engine has been started shut the fi mT enrichment to avoid system to avoid flooding the carburettor E p l x E if The real problems which could be experienced with these carburettors exclusively connected the fuel feeding The fuel feeding is regulated by the floater valve system located in the float chamber e n case impurities particles are present in the fuel these might prevent the admission valve from properly closing the level in th
29. ee fig 2 and leaner mixture by decreasing the above size The idle jet can be reached removing the carb float chamber A richer carburetion is attainable by turning the air screw B clockwise see fig 1 on the contrary by unscrewing you get a leaner carburetion It is suggested to gradually perform the adjustment by 5 10 turns per time Then check the result The adjustment of the carburation at mid range is performed by means of e The conical needle e The needle jet the conical needle acts as a shutter on the needle jet and its axial position is determined by the throttle gas opening Thanks to its particular conical configuration when the throttle opens gradually the needle gradually releases the spray nozzle hole and regulates the gasoline flow The conical needle and the spray nozzle have been chosen to satisfy most of the conditions and as a rule it not necessary to replace them with others having different characteristics The carburetion setting is performed by lifting or lowering the needle vs the throttle gas 24 MAN 051 ING We will get a richer carburetion by lifting the needle that is by moving down the retainer clip to a lower notch and on the contrary a leaner carburetion is achieved lowering the needle that is by lifting the retainer clip to a higher notch see fig 3 On the picture is shown the basic needle adjustment To reach the conical needle proceed as follow screw out the upper locking ri
30. es and suggested remedy turning the key to RUN position Bad EL NN Check connections and K MN s strip fuse after checking for eventual reversal of M polarity Replace Battery connections loose Check and tighten Electronic box or relay failure ae M UU T enters Starter cranks but engine won t Bad cable connection Check connectors start when turning the key in RUN position failure Apply to authorized Service Centers fuel pipe on carburettor Check reed We E Replace We E Engine starts but it stops after a cable connection Check stator connector few seconds when turning ie Apply authorized Service vu M key in RUN position UM carburettor adjustment ie carburettor adjustment screw l see seci 3 3 The starter cranks also the box failure Apply 5 Service engine is running m Starter relay remains excited Replace starter relay Rough idle Bad carburettor adjustment Check carburettor adjustment see screw l sect 3 3 Drop in engine performance Check piston Bad carb adjustment Check carburettor adjustment see sect 3 3 Check and clean Clutch engages at too high RPM Excessive wear of friction material Check clutch see sect 4 1 Oil leakage between hub and drum Clean and degrease carefully Exhaust too noisy Damaged muffler Check and replace if necessary Damaged or lost springs Damaged exhaust header 41 MAN 051 ING 4 6 ENGINE AND
31. gits there can be exceptions in some special cases Other numbers stamped on the crankcase or on other surfaces of the motor refer to various manufacturing processes and do not identify the engine NOTE In case of need for spares and when contacting the AME Support Centers please always refer to the Motor Identification Number and to the motor model 5 MAN 051 ING 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 section 3 Whenever the engine or a component is disassembled it is necessary to always follow the under shown instructions for proper reassembly 2 1 INSTALLATION SKETCH OF THE ENGINE ON THE CHASSIS iet pr 9 i T sa li am 6 MAN 051 ING 2 2 INSTALL THE WATER COOLING SYSTEM only for F3 F4 BEFORE INSTALLING THE RADIATOR PREASSEMBLE THE FOLLOWING COMPONENTS INSTALL THE 4 RUBBER DAMPENERS IN THE RADIATOR FIXING HOLES SEE FIG 1 PLACE THE RADIATOR SUPPORT BRACKET BETWEEN THE RADIATOR FIXINGS BY TILTING ONE END AND INSERTING IT THROUGH THE RUBBER DAMPENERS SEE FIG 2 NOTE OIL THE BRACKET ENDS AND THE DAMPENER HOLES FORAN EASIER INSERTION RADIATOR SUPPORL BRACKET 7 MAN
32. into the clutch the clutch dragging speed will slightl increase This overheats and deteriorates the components of the clutch In case this happens by accident stop the engine immediately and degrease the clutch drum and hub with specific solvents Check the sprocket status after each race or test and replace if necessary A bad alignment of the sprocket with the axle sprocket or the lack of oil will damage the sprocket beyond repair Check the clutch Every 5 hours of use When metallic noises are heard inside the clutch fthe kart dragging speed exceeds 5000 RPM Every time the clutch has overheated presence of smoke o smell of burning To check the clutch you must remove the clutch cover and the clutch drum Replace the clutch Whenever the thickness of the friction material see drawing is lower than 1 5mm on point A of the clutch or if the body diameter is lower than 82 5mm Whenever the external friction material in the A portion of the clutch is very rough wear or degradation of the friction material due to overheating A ATTENTION In case the friction material has been totally worn out and there has been a metal contact between the clutch body and the clutch drum it is necessary to replace the clutch drum Em m de c Ls LI ias MIN dB 5mm 37 MAN 051 ING 4 2 INSTRUCTIONS FOR THE DISASSEMBLY ASSEMBLY OF THE CL
33. l is sent to the electronic box In RUN position the battery is connected to the system and the stop signal is removed In START position the battery is always connected and the electric starter operation signal is sent to the electronic box The START position can be stable or recovered by means of a return spring In this case once the engine is started the spring automatically brings the key back to the RUN position AN ATTENTION The starting key assembly is provided with two original keys It is recommended to separate the keys and to keep one in a protected place In case of loss of both keys it is necessary to replace the complete assembly The starting procedure from STOP position is as follows A Turn the key to RUN position this connects the battery B Turn the key to START position to start the engine the electric starter is immediately disengaged when turning the key to RUN position or when the electronic box detects an engine RPM higher than 2000 RPM C When the engine is started the key can be left both in START position key assembly without return spring or in RUN position We suggest for practical reasons to always turn the key to RUN position this allows with a single tripping to stop the engine STOP position or to restart it in case the engine is stopped START position Note in case the engine is stopped with the key in START position key assembly without return spring to restart i
34. let us assume that you read a max of 12500 engine RPM From table 2 to achieve a max RPM of 13500 operating limit for F4 engine version a sprocket ratio from 7 08 and 6 96 should be used having used during the tests a sprocket ratio of 6 5 and having achieved 12500 RPM From table 1 with these values a sprocket ratio of 12 85 or 12 83 should be used or having a Z 11 on the engine sprocket a ratio of 11 77 should be used SPROCKET RATIO TO ACHIEVE MAX 13500 RPM F3 e F4 Tab 2 Max Engine Sprocket ratio RPM during i a ZEE kas ida id aL FIS em es ser re vas roe am as sa se sas 751 7 73 795 817 838 8 60 925 9 47 969 12600 5 89 6 11 632 54 675 739 5 66 8 80 9 54 ep s 571 592 613 6 33 ET 875 6 96 7 17 9 03 ECIEQECIEOE ESOS 786 6 65 ee os 104 aoe 864 88 6 16 8 36 655 6 75 6 95 734 753 sm 8 32 569 588 827 646 6 65 6 85 7 04 123 8 00 820 5 36 8 56 ser ss ss sso eor ass sos one on o 1m vio am um s 5 09 628 647 666 684 703 722 741 759 8 797 8 16 834 14800 spa s sae szs s s san ses 721 vao raz 175 sz aa ass scs sat 57 sos es oss 120 vas oor Las
35. n be checked by placing the engine in horizontal position and unscrewing the oil level plug If the level is correct you should see a light outcome of oil otherwise top up discharge the oil Unscrew the oil level plug n 3 on the picture and loosen the oil drain plug to let air in the gearbox 3 2 GASOLINE AND OIL Use leaded super or unleaded green gasoline mixed with oil at 496 It is possible to use synthetic oils or oils containing Castor oil As Castor Oils create gummy residues it is necessary to check and clean at least every 10 hrs the piston and the head Our experience dictates use of oils such as SHELL ADVANCE RACING X ELF HTX 909 Once the fuel tank is filled make sure that the gasoline reaches the carburettor or the pump F4 version before starting the engine Never use the electric starter to suck the gasoline as this could discharge the battery SUGGESTION Disconnect the plastic tube on the carb and the vent tube on the tank and pressurize the vent tube until the gasoline comes out from the tube on the carb Make sure that there is no air in the tube Connect the tube on the carb and on the vent 22 MAN 051 ING 3 3 CARBURETTOR ADJUSTMENT GUIDE _ gi L 1 1 T O 1 wd b RICH Z I IDLE JM 1 T 0 e T O ADJUSTMENT le SCREW g o 1 T O TURNS OPEN Hereinafter are shown some basic carbs settings according to the engine version
36. n every time the engine is stopped If the key is left in RUN position for a long time even if the engine is stopped the battery would be discharged completely Never disconnect the ground cables with eyelets ground cables when the engine Is in operation Disconnecting the battery when the engine is in operation DOES NOT increase the engine performance Vice versa the ignition advance could become very irregular at low RPM thus reducing the performance To fasten the eyelet terminal groundings of the wiring harness always use flat or open washers Never use tab washers When disconnecting the connectors always press the fixing tongues Always pull the connectors to disconnect NEVER PULL THE CABLES The electronic box and the starting relay must always be installed with their connectors towards the bottom to avoid back water dampness or dirt in the connector body Always correctly fix the H T coil with both screws make sure that the laminations pack on the H T coil is connected to the engine with the grounding cable copper cable or screws The eyelet connector must be directly in contact with the lamination pack on the H T coil Never use H T coils different than the original coil on the engine Use of a different coil may cause damages to the electronic box The digital assembly needs use of a resistive spark plug cap or spark plug The resistor value must be equal or higher than 5 Kohm Avoid use of resistive H T cables
37. nfluenced by atmospheric factors such as temperature and pressure The more the temperature drops the more the air density increases and consequently there will be more molecules of gas in the same volume As the carb mixes always the same fuel quantity this would be insufficient and the carb will provide a leaner mixture In these conditions as you are aware when operating with a leaner mixture the engine runs the following risks overheating insufficient lubrication detonation seizure for this reason the carburettor setting must be adjusted by increasing the max jet size by about 2 3 points for every 6 C external temperature drop Of course on the contrary the more the temperature rises the more the carburetion becomes richer and gives origin to less critical consequences than the ones experienced with a leaner carburetion So also in this case it is suggested to optimize the carb setting by decreasing the max jet size by about 2 3 points for every 6 C external temperature increase The variation of the atmospheric pressure which is significant when varying the altitude at which the engine is Operating gives origin to such a phenomenon by decreasing the altitude the atmospheric pressure increases consequently in the same air volume sucked by the engine more molecules of gas are present Therefore in this case too a carb adjustment is required increase the max jet size by about 2 3 points for every 350m altitude decr
38. ng on the carb then pull off the throttle gas together with the needle release the throttle cable and screw out the fixing screw on the throttle gas The adjustment of the carburetion at top RPM is mainly performed by means of e The max jet By increasing the H max jet size see fig 2 we get a richer carburetion and vice versa a leaner one by decreasing the jet size To reach to the max Jet screw out the central plug on the float chamber see fig 4 or disassemble the float chamber itself As anticipated there is no clear distinction among the areas of influence of the different components as they interact and influence each other As a matter of fact the max jet affects not only the carburetion at wide open throttle gas but also the whole mid range carburetion even if less sensibly vs the needle position indirectly the needle position slightly influences the carburetion at completely opened throitle In the same way when the throttle is slightly opened the effects of the min jet and the air screw superimpose with the effect of the conical needle position To properly adjust the carburetion according to the ambient conditions we are giving some indicative parameters to adapt the max jet size as a function of the variation of the ambient temperature and the altitude at which the engine is operating As you know carburetion that is the exact quantity of fuel to be mixed to a given quantity of air is i
39. or end and electrodes covered with black symptoms listed aside shady soot Ignition difficulties 7 JA Note a wet or oilv electrode could also mean Alwavs use a colder than standard spark plu an excessivelv rich mixture with hot climates COMPARISON TABLE BASED ON THE THERMAL DEGREE HOT 5 WO8CS BR9EG N54R WO7CS BR10EG N52R _ hh WO6CS BR11EG COLD 33 MAN 051 ING 3 13 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 components con rod roller cages bearings etc will be such as to drastically reduce the life of the engine itself It is therefore important that the user respect the operating limits imposed by the manufacturer The operation limit for the Reedster is 14000 RPM for and F4 15000 RPM for F2 and 16000 RPM for F1 the RPM limiter is calibrated at these values AM ATTENTION Never exceed the above limit No obligation of IAME exists in case the above limit is exceeded In case the user wishes to optimize on the track the sprocket ratio in order to achieve the best possible performance without abusing the engine follow the under shown recommendations The engines are supplied with a 12 teeth sprocket pitch 7 775 mm but 11 and 13
40. rankcase by 4 studbolts The crankshaft is of the built up type and supported by two ball bearings It is of steel alloy hardened and tempered as is the connecting rod which is machined from the full The rod runs on roller bearings on both ends The crankcase houses a balance shaft driven by two gears which rotates opposite to the crankshaft thus reducing the engine vibrations The digital ignition with capacitive discharge is fed by a magneto which generates the spark energy for the starting of the engine guarantees the advance timing through an integrated pick up and recharges the battery The ignition includes a digital electronic unit the stator rotor the starter relay the H T coil a switch key assembly and of course the wiring harness with a 5A fuse which connects the whole system The electronic box which controls the advance the rev limitation imposed by the CIK FIA rules and the engine start stop logic also integrates the voltage regulator and the ignition control circuit The starter relay Solid type SSR protected from short circuits and overloads supplies the power for the electric starter and is controlled by the electronic unit The spark is generated also without a battery it is therefore possible in case of emergency to start the engine with an external starter unit When the starter key is in the RUN position the electric starter activates a Bendix type gear which engages the starter ring assembled on the
41. s during the break in the nuts tend to become loose refer to the attached table 3 6 RPM LIMITATION The electronic box integrates an RPM limiter which prevents the engine from exceeding 14000 RPMs for both F3 and F4 versions 15000 RPM for F2 vers and 16000 RPM for F1 vers The limit of 16000 RPMs cannot be exceeded otherwise the engine could be damaged by the extremely high RPM N ATTENTION Do not keep the engine for a long time at the RPM at which the limiter Is operating This would cause malfunctions on the induction and damage the reed valve When choosing the sprocket ratio always refer to maximum limit so that the RPM limiter only intervenes on the longer straights on the track 3 INLET SILENCER Make sure that the inlet holes on the filter are towards the front side of kart and that they are not plugged Make sure that the clamp on the carb is not loose and that the filter is well fastened to the rail side chassis by means of a craddle support Once a while clean the inside from oil deposits If necessary remove the rubber filter union and clean it with gasoline or solvent 28 MAN 051 ING 3 8 3 9 EXHAUST SYSTEM Before every test make sure that the springs are well hooked and properly 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 hrs open the pipe end
42. strength according to the track characteristics and ambient conditions In case of a high level setting for which a specific experience is required it is impossible to give instructions in a few words Our target is to give here simple instructions for setting the best adjustment according to the operation conditions As a rule we consider three ranges of operation the idle RPM and low RPM attainable with throttle lever slightly opened the mid RPM or intermediate RPM attainable with intermediate opening of the throttle lever and the max RPM attainable with max opening throttle lever In a float chamber carburettor such as this carburettor specific devices are available to check the carburetion at each RPM range of operation each of these devices intervenes on a specific area as described hereinafter even if there is no clear distinction among the different areas The idle RPM can be adjusted by means of the A screw see fig 1 which intervenes on the throttle valve by slightly lifting or and lowering it lt is necessary to turn clockwise to increase the RPM and turn counterclockwise to decrease it A The carburetion at idle RPM can be set by means of Sy e idle jet in the float chamber e The idle emulsion tube located above the respective jet e The air mixture idle screw Generally for standard adjustments the emulsion tube is not concerned A richer mixture can be obtained by increasing the idle L jet size s
43. t turn the key in RUN position and then again to START position to activate the electric starter with the key in RUN or START position and if the engine is stopped to start the engine an external starter unit can also be used In case the engine cannot be started within 5 seconds check that fuel gets to the carb interrupt and try again after 15 seconds Short and frequent tries are better than long ones 2 MAN 051 ING To stop the engine proceed as follows A Turn the key in STOP position both from RUN position 1 tripping or from START position 2 trippings 3 5 ENGINE BREAK IN The break in of the engine must be performed following a few fundamental recommendations 1 Adjust the carburetion Start with a basic adjustment on the rich side 2 Warm the engine gradually for about 5 minutes at half throttle making a few laps at low speed gently closing and opening the carb throttle if a tachometer is installed never exceed 10 000 11 000 RPM Never keep the same RPM for a long time 3 Increase the speed for 5 minutes at throttle 3 4 opening Never keep the same RPM for a long time 4 Increase the speed for 5 minutes at max speed on the twisty parts 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 a Arrenrion Once the break in is over and the engine is cold check the torque of the exhaust header nuts a
44. ter forced e Ignition Digital electronic with integral rev limiter e Battery charge With integral generator e Electric start 12V 0 30 Kw starter e Clutch Automatic dry centrifugal 14000rpm F3 e F4 15000rpm F2 16000rpm F1 e Min water temperature 45 C e Max water temperature 65 C A ATTENTION Never exceed the above limits no obligation of IAME exists in case the above limits are exceeded 2 MAN 051 ING 1 3 CONTENTS OF THE PACKING Each Parilla Reedster 125cc engine is supplied with the under shown components and accessories Exhaust springs e Exhaust system 1 INDUCTIONSYSTEM e Inlet silencer 1 only F4 ELECTRICALSYSTEM O e Battery 12V 0 0 L 4d e Battery strip e Battery fixing clamps e Electronic box e Starting relay e coil Starting Key assembly e e Fixing clamps only F3 e F4 1 only F3 e F4 I k 4 yt jO lt e d 3 MAN 051 ING 1 4 ACCESSORIES 1 EXHAUST SYSTEM NGK SPARK PLUG CLUTCH COVER H T COIL THERMOSTAT CARBURETTOR FUEL PUMP RADIATOR SUPPORT KIT INLET SILENCER WATER HOSES KIT RADIATOR 4 MAN 051 ING 1 5 MOTOR IDENTIFICATION NUMBER The official motor identification number can be found stamped on the lower front right part of the crankcase near the reed group see fig The number normally includes a letter followed by 4 di
45. use a malfunction in the vibration reduction system and damage the engine beyond repair a F er PISTON AT T D C 2 A Zam poa purs i Th M M s Aur UC C N A BALANCE SHAFT NOTCH es lt E C L 14 1 t 4 CRANKSHAFT y ger v if E if eee y RP REF NOTCH SQ i n gt h f F ka E 1 1 um bom L j 1 il j KC A 7 bn l p d n ma Au 8TH kum C Pes g Muf Fa 1 lon ET P x E s fi u i gt 1 V J GE AR amp HEF SSO Obr V MARKINGS F 39 MAN 051 ING 4 4 SCHEDULED MAINTENANCE Following some simple maintenance recommendations will allow the engine to perform more reliably and have a longer life SCHEDULE COMPONENTS ACTIONS AND COMMENTS Before using Exhaust fitting springs Check status Muffler Check status and fixing Check wear Engine sprocket Check alignment with axle sprocket Engine chain Check wear tensioning and oil chain After use Replace Every 5 10 hrs Remove cover see fig Bendix assembly clean internally Open clean Clutch Open check status of parts Every 10 hrs Every 20 hrs 40 MAN 051 ING 4 5 IROUBLESHOOTING Below are some common faults their probable caus
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