IAME M1 60cc Assembly Instructions And User'S Manual Download Page 5 | Manualshive

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MAN-88 – UK

2-

ENGINE IDENTIFICATION NUMBER

EXHAUST GROUP

SPARK PLUG NGK

CLUTCH COVER

CYLINDER & CYLINDER HEAD

THERMAL PROTECTION SAFETY COVER

INTAKE SI FIXING CLAMP

INTAKE GROUP

+ TILLOTSON HS-323A CARBURETTOR

COIL-SWITCH CABLE

COIL WITH SPARK PLUG CAP

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Summary of Contents for M1 60cc

Page 1: ...ASSEMBLY INSTRUCTIONS AND USER MANUAL MAN 088 M1 60cc...

Page 2: ...hassis 3 6 Install the clutch cover 3 7 Electrical connection 4 Gasoline and Oil 5 Tillotson HS 323A Carburettor Adjustament 6 Starting and Stopping the engine 7 Engine Breaking In 8 Inlet Silencer 9...

Page 3: ...m cylinder and is secured to the cylinder with through studs The crankshaft is built and supported by ball bearings It s made of alloy steel hardened and tempered as well as the connecting rod which a...

Page 4: ...he above limits are exceeded 1 CONTENTS OF PACKING Each engine is supplied with the accessories under shown EXHAUST GROUP Quantity Exhaust Muffler Gasket 2 Exhaust Manifold with restrictor 11 5mm 1 Ex...

Page 5: ...FICATION NUMBER EXHAUST GROUP SPARK PLUG NGK CLUTCH COVER CYLINDER CYLINDER HEAD THERMAL PROTECTION SAFETY COVER INTAKE SILENCER FIXING CLAMP INTAKE GROUP TILLOTSON HS 323A CARBURETTOR COIL SWITCH CAB...

Page 6: ...cludes a letter followed by 4 digits Other numbers stamped on the crankcase or other surfaces refer to various manufacturing processes and do not identify the engine NOTE In case of need for spare par...

Page 7: ...his section and can start reading from section 4 Whenever the engine or a component is disassembled it is necessary to always follow the under shown instructions for proper reassembly 3 1 INSTALLATION...

Page 8: ...ROTECT THE INTERNAL PARTS REMOVE THE EXHAUST COVER GASKET INSTALL THE SCREWS AND THE WASHER ON THE SAFETY COVER OF THE MUFFLER n 2 M6x95 n 1 M6x12 n 3 WASHER 24 6 6 n 3 ELASTIC WASHER FOR M6 POSITION...

Page 9: ...HE MUFFLER WITH ITS SAFETY COVER ON THE ENGINE AND TIGHTEN BUT NOT DEFINITELY ALL SCREW OF FIXING WHEN THE POSITION OF THE ALL COMPONENTS IS CORRECT TIGHTEN DEFINITELY ALL SCREWS N 3 SCREWS WITH 5 mm...

Page 10: ...IONS ARE IN MILLIMETERS INSTALL THE MOTOR MOUNT MAKE SURE TO USE M8 ALLEN SCREWS WITH A LENGTH SUCH AS TO ENGAGE IN THE CRANKCASE A THREADED PORTION LENGHT OF 16 19MM THE SCREW MUST PROTRUDE FROM THE...

Page 11: ...HTEN DEFINITELY THE SCREWS WITH THE 5MM ALLEN WRENCH TORQUE AT 6 10 Nm 50 90 in lb Pre assembling N 2 SCREWS M6x95 INTO THE INLET MANIFOLD AND TAKE A POSITION OF THE CARBURETTOR AS IN PICTURE BETWEEN...

Page 12: ...WITH THE FLATHEAD OR PHILLIPS SCREWDRIVER CONNECT BY APPROPRIATE PIPE THE INTAKE PRESSURE MANIFOLD ON THE CARBURETTOR AND THE INTAKE PRESSURE MANIFOLD ON THE CRANKCASE CONNECT BY APPROPRIATE PIPE THE...

Page 13: ...ELY THE CLAMPS UNTIL THE CHAIN IS INSTALLED AND PROPERLY ALIGNED CHECK THE ALIGNMENT OF THE ENGINE SPROCKET AND THE AXLE SPROCKET WITH A STRAIGHT EDGE INSTALL THE CHAIN PITCH 7 775mm MOVE THE ENGINE O...

Page 14: ...ICAL CONNECTION CONNECT THE COIL CABLE SMALL ONE TO THE TERMINAL ON THE COIL CONNECT THE COIL CABLE AT THE TERMINAL ON THE ON OFF SWITCH INSTALL THE SPARK PLUG ON THE CYLINDER HEAD AND INSTALL THE SPA...

Page 15: ...o check and clean at least every 5 10 hours the piston and the cylinder head Our experience dictates use of oils such as WLADOIL K 2T KART RACING OIL SHELL ADVANCE RACING M ELF HTX 909 Once the fuel t...

Page 16: ...e necessary to reset the carburettor to optimize the performance of the engine ATTENTION Never lean too much as lean mixture will overheat engine and cause seizure The adjustment of the High screw is...

Page 17: ...g the switch on the OFF position 7 ENGINE BREAKING IN The breaking in of the engine must be performed following a few fundamental rules Adjust the carburetion Start with an adjustment on the rich side...

Page 18: ...s still avoid useless accelerations which can overheat and deteriorate the clutch early Lubrificate the chain before each test immediately after each session and check the engine sprocket Replace if n...

Page 19: ...y for blocked the crankshaft Clutch wrench CH 24 Special tool S 1436 2 3 Remove drum nut N 1 nut M10 12 Point wrench 17 mm 4 Remove the external washer the drum with roller cage the O Ring and the int...

Page 20: ...internal washer and the O ring ATTENTION install washer with chamfer towards internal part of engine Clean the roller cage and grease it before installing on the crankshaft 1 Install the clutch drum...

Page 21: ...mixtures can generate the same final look which can be also achieved with a hot or cold spark plug See table an excessively warm spark plug shows the symptoms listed aside ATTENTION Use a warmer spark...

Page 22: ...ket ratio in order to achieve the best possible performance without abusing the engine follow the under shown recommendations The engines are supplied with a 10 or 11 teeth sprocket pitch 7 775mm Tabl...

Page 23: ...cket and Z 72 on the axle sprocket a ratio of 7 20 is found Make a few laps on the track and let us assume that you read 11 000 max engine RPM From the table 2 to achieve a max RPM of 12 500 RPM opera...

Page 24: ...and connections Engine mount and clamps Check torques After use Chain Check status and oil chain Engine External cleaning Engine used in rain conditions Clean carefully the engine interior and the clu...

Page 25: ...he prescribed clearance between cylinder and new piston is 0 07mm The effective piston diameter has to be verified at 15mm from the base perpendicularly to the piston pin Size of the liner to be match...

Page 26: ...t can be made every 300lt MAIN BEARING The replacement can be made every 300lt CONROD The replacement can be made every 600lt Anyway it must be replaced whenever the big end hole ovalization exceeds 0...

Page 27: ...k carburettor adjustment see Sect 5 Drop in engine performance Bad compression Check piston Bad carburettor adjustment Check carburettor adjustment see Sect 5 Insufficient fuel flow Check fuel flow li...

Page 28: ...x0 8 2 CARBURETTOR MANIFOLD SCREWS Allen 4 5 6 45 50 M6x1 2 INLET MANIFOLD SCREWS Allen 5 6 8 50 70 FIXING CLAMP 1 FIXING CLAMP SCREW Screwdriver 6 8 50 70 M4x0 7 2 COIL SCREWS Allen 3 5 6 45 50 M5x0...

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