IAME Parilla x30 125cc RL-TaG Assembly Instructions & User Manual Download

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MAN-043/B

ASSEMBLY INSTRUCTIONS

USER MANUAL

20/10/11

Summary of Contents for Parilla x30 125cc RL-TaG

Page 1: ...MAN 043 B ASSEMBLY INSTRUCTIONS USER MANUAL 20 10 11...

Page 2: ...lencer 2 10 Install the exhaust Section 3 ENGINE USE 3 1 Charging of the oil in the gear box 3 2 Gasoline and oil 3 3 Carburetor adjustment guide 3 4 Starting and stopping the engine 3 5 Engine break...

Page 3: ...ludes a digital electronic unit the stator rotor the starter relay the H T coil a switch key assembly and the wiring harness with a 5A fuse which connects the whole system The electronic box which con...

Page 4: ...Reed valve in the crankcase Carburettor Membrane TRYTON HOBBY 27 C 26 Cooling Water forced Ignition Digital with integrated rev limiter Battery charge With integral generator Electric start 12V 0 30...

Page 5: ...rburettor 26 1 Intake silencer 1 ELECTRICAL PLANT Battery 12 V 9 Ah 1 Battery support 1 Battery strip 1 Battery fixing clamps 2 Electronic box power pack 1 Starter relay 1 H T coil 1 Starting key asse...

Page 6: ...ST 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 N...

Page 7: ...r normally includes a letter followed by 4 digits there can be exceptions in some special cases Other numbers stamped on the crankcase or other surfaces of the motor refer to various manufacturing pro...

Page 8: ...ssis 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 disass...

Page 9: ...SEMBLE THE PUMP FIXING BRACKET ON THE CLAMP N 2 SCREWS M6x12 AND PLACE THE CLAMPS ON THE REAR CROSS RAIL N 2 SCREWS M6x25 INSTALL THE PUMP ON THE BRACKET N 1 SCREW M8x45 WITH WASHER AND NUT SEE FIG 2...

Page 10: ...THE FOLLOWING COMPONENTS 5 INSERT THE 4 RUBBER DAMPENERS INTO THE FIXING HOLES ON THE RADIATOR SEE FIG 5 6 PLACE THE RADIATOR SUPPORT BRACKET BETWEEN THE RADIATOR FIXINGS BY TILTING ONE END AND INSERT...

Page 11: ...ET RADIATOR CAP SIDE N 1 SCREW M6x90 AND N 1 SCREW M6x85 WITH NUT INSTALL THE L SHAPE BRACKET ON THE LOWER RADIATOR CLAMP AVAILABLE IN DIFFERENT DIAMETERS 28 30 32mm 2 SCREWS M6x12 AND FIX IT TO THE T...

Page 12: ...TO THE FITTINGS ON THE PUMP OUTLET AND THE ENGINE INLET TIGHTEN WITH STEEL CLAMPS ON BOTH SIDES SEE FIG 11 10 TO INSTALL THE THERMOSTAT REGULATING THE WATER TEMPERATURE CUT THE HOSE CONNECTING THE FIT...

Page 13: ...TS AND THE EXHAUST COVER 2 3 2 MAKE SURE THE EXHAUST GASKET IS IN SEAT AND INSTALL THE EXHAUST HEADER SEE FIG 2 2 3 3 INSTALL THE TWO WASHERS 8mm 2 3 4 INSTALL THE TWO 2 NUTS M8 TORQUE AT 18 22 Nm 160...

Page 14: ...TALL THE CARBURETOR 2 5 1 REMOVE THE PLASTIC PLUG FROM THE INLET MANIFOLD SEE FIG 4 ATTENTION MAKE SURE THAT THE PRESSURE HOLE ON THE GASKET IS NOT PLUGGED 2 5 2 5 2 INSTALL THE CARBURETOR TWO 2 NUTS...

Page 15: ...L THE CHAIN IS INSTALLED AND PROPERLY ALIGNED 2 6 2 CHECK THE ALIGNMENT OF THE ENGINE SPROCKET AND THE AXLE SPROCKET WITH A STRAIGHT EDGE SEE FIG 7 2 6 3 INSTALL THE CHAIN PITCH 7 775 SEE FIG 8 2 6 4...

Page 16: ...WIDEN THE CHAIN OPENING WITH A FILE TO CHECK THIS WE SUGGEST TO INSTALL THE SPROCKET WITH THE HIGHEST AVAILABLE TOOTH NUMBER 5 mm ALLEN 2 7 2 CONNECT THE COIL COPPER CABLE ON THE HOLE ON THE CRANKCASE...

Page 17: ...BOLT DEPENDING ON THE TYPE OF CHASSIS NOTE THE BOX AND CLAMPS ARE PROVIDED WITH VARIOUS HOLES WHICH ALLOW INSTALLATION ON ALL KIND OF CHASSIS 10mm BOX WRENCH 2 8 3 INSERT THE BATTERY IN THE BOX AND F...

Page 18: ...RE PROPERLY INSERTED TO GUARANTEE THE BEST POSSIBLE CONNECTION OF THE TERMINALS 2 8 6 FASTEN THE CABLE FROM THE ELECTRIC STARTER TO THE STARTER BODY WITH A PLASTIC CLAMP SEE FIG 19 ATTENTION THIS OPER...

Page 19: ...F THE SECOND GROUND CABLE IN THE HARNESS CLOSE TO THE COIL CABLE TO THE H T COIL BY MEANS OF THE M6 NUT FIXING THE COIL SEE FIG 22 TORQUE AT 8 10 Nm 70 90 in lb ATTENTION THIS OPERATION IS EXTREMELY I...

Page 20: ...NNECT THE STARTER RELAY TO THE 4 POLE TERMINAL IN THE WIRING HARNESS SEE FIG 27 ATTENTION MAKE SURE THAT THE FIXING TONGUES ARE PROPERLY INSERTED TO GUARANTEE THE BEST POSSIBLE CONNECTION OF THE TERMI...

Page 21: ...BOX AND THE STARTER RELAY SEE FIG 30 NOTE CLEAN AND DEGREASE THE FAIRING FIXING SURFACE WHERE THE STRAP IS TO BE PLACED TO GUARANTEE THE BEST POSSIBLE STRAP ATTACHMENT 2 8 16 DRILL A FEW HOLES IN THE...

Page 22: ...HE TERMINALS 2 8 19 SCREW THE SPARK CAP ON THE H T COIL SEE FIG 34 2 8 20 FIX THE CAP TO THE H T CABLE WITH A PLASTIC CLAMP SEE FIG 35 INSTALL THE SPARK PLUG TORQUE AT 20 26 Nm 175 230 in lb INSTALL T...

Page 23: ...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 FLEXIBLE ON THE EXHAUST HEADER AND...

Page 24: ...arge the oil through the oil level plug 3 2 GASOLINE AND OIL Use leaded or unleaded Premium gasoline 92 RON MON mixed with oil at 4 25 1 2 Use oils containing Castor Oil which guarantees an optimized...

Page 25: ...om closed to approximately 1 T O 1 turn I Close by further 1 T O after contact with throttle lever Start the engine and warm it If RPM too high adjust counterclockwise until clutch is disengaged Turn...

Page 26: ...start the engine the electric starter is immediately disengaged when turning the key to KEY position or when the electronic box detects an engine RPM higher than 1 500 RPM C When the engine is running...

Page 27: ...ome loose refer to the attached table 3 6 RPM LIMITATION The electronic box incorporates an RPM limiter which prevents the engine from exceeding 14 000 15 500 or 16 000 RPM depending on the engine ver...

Page 28: ...performance is achieved with a total exhaust lenght of L 450 455 mm Where L is measured from the flange on the exhaust header up to the first welding on the first cone of the exhaust muffler see drawi...

Page 29: ...e positive terminal after Always disconnect the battery in opposite order Recharge the battery at least once every 6 months Never let the battery tension dropping under 8V as whenever it drops under t...

Page 30: ...ly in contact with the laminations pack on the H T coil 8 Never use H T coils different than the original coil on the engine Use of different coil may cause damages to the electronic box 9 The digital...

Page 31: ...nerate 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 symptoms listed aside ATTENTION Always use a warmer than standard s...

Page 32: ...dations The engines are supplied with a 11 teeth sproket pitch 7 775 mm but 10 and 12 teeth sprockets are available as accessories Table 1 shows the various ratios between the sprocket on the axle and...

Page 33: ...ratio of 7 70 is found Make a few laps on the track and record the maximum engine rpm achieved Let us assume that you detect 13 600 RPM From the Table 2a to achieve a max RPM of 14 000 RPM operating...

Page 34: ...MAN 043 B 32...

Page 35: ...he sprocket beyond repair Check the clutch every 5 hours of use When metallic noises are heard inside the clutch If the kart dragging speed exceeds 6000 RPM Every time the clutch has overheated presen...

Page 36: ...t crankshaft from turning Piston fitting P N 10271 3 Remove nut 1 nut M10 12 point wrench 17 mm 4 Remove the external washer the drum complete with roller cage the internal washer 5 Remove the special...

Page 37: ...rench P N 10270 12 point wrench 30 mm torque at 100 110 Nm 885 970 in lb 4 Install the internal washer ATTENTION install washer with bevel towards internal part of the engine Clean the roller cage and...

Page 38: ...EMBLE 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...

Page 39: ...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...

Page 40: ...M STARTER HEAD see Fig 6 ATTENTION WHEN EXTRACTING ROTOR THE BRUSHES MAY SPRING OUT FROM THEIR SEATS REPLACING THE BRUSH A UNSCREW THE 2 SCREWS M4 D RETAINING THE PLATE E see Fig 7 PHILLIPS SCREWDRIVE...

Page 41: ...GS 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 IT WIT...

Page 42: ...RUSH IN PLACE BY PRESSING TOWARDS THE OUTER AND CLAMP IT WITH AN IRON WIRE BENT AS A HOOK REPEAT THE SAME PROCEDURE TO INSTALL THE BRUSH B see Fig 14 INSTALL THE STARTER ROTOR BETWEEN THE BRUSHES AND...

Page 43: ...ig 18 PHILLIPS SCREWDRIVER CHECK THAT THE STARTER ROTOR ROTATES FREELY CONNECT THE INPUT WIRING TO THE STARTER WITH THE SCREW M4 see Fig 19 PHILLIPS SCREWDRIVER SECURE THE WIRE TO THE STARTER BY MEANS...

Page 44: ...and connectors Check status and connectors Grounding of engine and electronic box Check status and connectors Engine mounts and clamps Check torques After use Battery Disconnect Chain Check status an...

Page 45: ...duction system Check status and connection on fuel pipe Replace gaskets and membranes on carburetor Check reed petals Replace if necessary Engine starts but it stops after a few seconds when turning t...

Page 46: ...d 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 engine must be cleaned Spr...

Page 47: ...MAN 043 B 45...

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