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TANGO125 ANG

1. LL Z Q N I Engine disassembly I Engine 7 LOOSE Nut 1 Remark e Place a folded aluminium sheet between the teeth of the primary gear and those of the hood Jake care not to damage the gear teeth 8 REMOVE Nut Particular washer Primary gear 1 Cotter 2 Rotarv filter 3 D yo 9 y 3 4 OIL PUMP Remark e The oil pump can be removed with the assembled engine in the frame To be able to do it take the following parts out e Clutch e Rotary filter l REMOVE e Screw with washer oil pump 1 e Oil pump unit 2 e Oil impeller Engine disassembly Engine 3 5 START PEDAL SHAFT Remark e The start pedal can be removed with the assembled motor in the frame To be able to do it take the following parts out e Exhaust e Foot rest Brakes pedal e Change pedal e Clutch I REMOVE Clamp ring 1 Particular washer 2 Star system gear 3 e Particular washer Clamp ring 2 EXTRAER Torque spring 1 e Star shaft unit 2 Particular washer 3 Clamp ring Engine disassembly Engine 3 6 DISASSEMBLY OF THE START SYSTEM SHAFT WITH PEDAL HSIIONSA I REMOVE e Space washer 1 Torque spring 2 Washer 3 Start system gear 4 Clamp ring 5 e Start system shaft 6 3 7 CHANGE SHAFT Remark e The change shaft can be removed with the assem
2. The condition of the hermetic batteries can be controlled measuring the voltage in the terminal with a digital tester which can measure even tenth of volt In case that the voltage is below the specified one the battery should be recharged The standard voltage in the terminals of the battery should be 12 5V or more METHOD OF RECHARGE To recharge hermetic batteries it is necessary a battery charger with a stabilized outlet special for this type of batteries These batteries are sealed do not add fluids either open the caps since the characteristics will be altered damaging the battery Charges up 1 10 of its capacity should not take place SYSTEM TO DETERMINE TIME OF RECHARGE To determine the necessary time to load the battery the voltage in terminals should be measured with the tester Next observing in the chart the axis of voltage and draw a vertical line till crossing the slope of charge and the horizontal line till the axis of time in hours Example Observing the chart If the measure in terminals is I2V draw a vertical line up from the 12 till crossing the slope anda horizontal line until 8h approx The time to charge this battery would be of 8 hours approx Time of charge 11 5 12 0 12 5 13 0 Vollage cf the battery terminals Chart of time to charge in function of the voltage in terminals Chassis HOW TO DETERMINE BATTERY CONDITIONS To be able to determine if the battery
3. Clutch hood 2 Washer 3 Nut of the primary gear 4 Remark Assemble the primary gear with the letter out Place a folded aluminium or copper sheet a among the teeth of the primary gear 1 and the teeth of the hood gear 2 Engine assembly and adjustments 3 48 CLUTCH INSTALLATION I INSTALL Clutch hood 1 Pressure washer 2 Clutch drum 3 Clamp washer 4 Nut of the clutch drum 5 EL p 2 PRESS Nut of the clutch drum Remark Press the nut of the clutch drum 2 while hold the clutch drum with the universal support of the clutch 3 2 Nut of the clutch drum 6 0 Kgf m 60 N m Z2 3 BEND Rim of the clamp washer 1 on a top flat side of the nut 4 INSTALL Friction plate 1 Separators 2 Engine assembly and adjustments Engine Remark Install the plates and the separators alternately in the clutch drum beginning and finishing with friction plate e Lubricate all the plates and separators with motor oil before the installation e Make sure that each separator with its 90 dislocated projections is installed with regard to the previous one Continue with this procedure till all the separators have been installed 5 INSTALL Ball 6 INSTALL e Operation rod N I 1 Operation plate 2 Washer 3 e Nut of the operation rod N I 4 7 INSTALL Pressure pl
4. 6 PRESS Nut magneto flywheel Nut of the magneto flywheel 7 0 Kgf m 70 N m Remark Press the nut 1 while holding the steering wheel 2 with the supporter of the rotor 3 Be careful not to let the supporter of the rotor touches the rotor salient VS Rotor support 90890 01701 7 INSTALL ang guide Gasket of the chassis cover New Chassis cowling LS Screws of the chassis cover 1 0 Kgf m 10 N m 8 CONNECT Drive of the neuter switch Engine assembly and adjustments 3 52 CYLINDER AND PISTON I Cylinder 2 Special gasket 3 Cylinder gasket 4 Greed tang 5 Group of rings 6 Clamp bolt 7 Piston 8 Bolt Engine assembly and adjustments 3 53 CONTROL GEAR AND TIMING CHAIN 2 0 Kgf m 20 N m I Gasket 2 Strut unit of the timing chain 3 Guide of the timing chain intake 4 Control gear 5 Timing chain 6 Guide of the timing chain exhaust Engine assembly and adjustments Engine 3 54 RINGS PISTON AND CYLINDERS INSTALLATION HSIIONSA I Install according to the following sequence Expander oil ring 1 e Separator rings oil ring 2 Secondary ring scraper 3 Top ring compression 4 Remark e Install the rings with the manufacturer trademark upwards Lubricate the piston and the rings properly with motor oil 2 INSTALL Piston 1 Bolt 2 Clamp bolt New 3 Rem
5. Carbon sediment in the face and in the valve seating 2 CHECK Valve seating Groove Wear gt Polish the valve with emery 3 MEASURE Width of the valve seating a Unspecified gt Polish the valve with emery Width of the valve seating Inlet 0 9 1 1 mm lt Limit 1 6 mm Exhaust 0 9 1 mm Limit 1 6 mm Steps for measuring Apply blue ink of mechanics Dykem b in the face of the valve Install the valve in the cylinder head Press the valve against the guide and against its seating to make a visible mark Measure the width of the valve seating Where there was a contact between the seating and the front of the valve the ink will be removed f the seating width of the valve is big small or it is not centred it has to be redone Check and repairs 4 POLISH WITH EMERY Front of the valve Valve seating Remark e After correcting the valve seating or replacing the valve and its guide the seating and the front should be polished with emery Steps for fixing the valves Apply an abrasive thickness paste on the front of the valve Not to allow to enter the paste in the space between the rod and the valve guide Apply oil with disulphide molybdenum in the valve rod Install the valve in the cylinder head Rotate the valve until its front and its seating are uniformly polished at once eliminate the whole paste Remark To o
6. TABLER DE INSTRUMENTOS 14 CLAXON DC 12V 1A LAMPARA ILUMINACION TABLIER 12V 1 2W NEGRO VE VERDE 1B LAMPARA ILUMINACION TABLIER 12V 1 2W RELE DE CONTACTO 1C LAMPARA CONTROL LUZ INTENSIVA 12V 1 2W MARRON RO ROSA 1D LAMPARA CONTROL INTERMITENTES 12V1 2W CENTRAL INTERMITENTE 12V 2X10W 1E LAMPARA CONTROL NEUTRAL 12V1 2W BLANCO VI VIOLETA 1F LAMPARA ILUMINACION CUENTA R P M 12V1 2W INTERRUPTOR NEUTRAL zn MA Rae FARO DELANTERO REGULADOR DE TENSION AC DC 12 V 2A LAMPARA PRINCIPAL 12V 35 35W 2B LAMPARA POSICION 12V 5W VOLANTE MAGNETICO FARO INTERMITENTE DELANTERO IZQUIERDO FUSIBLE DE 10 A 3A LAMPARA INTERMITENTE 12V 10W CENTRAL ENCENDIDO CDI FARO INTERMITENTE DELANTERO DERECHO 4A LAMPARA INTERMITENTE 12V 10W BATERIA 12V CERRADURA DE CONTACTO RELE DE ARRANQUE ELECTRICO 12V 70A SENSOR T RMICO MOTOR DE ARRANQUE RESISTENCIA BOBINA A T PULSADOR DE ARRANQUE FARO INTERMITENTE TRASERO DERECHO 26A LAMPARA INTERMITENTE 12V 10W CONMUTADOR LUZ CORTA E INTENSIVA FARO PILOTO STOP COMUTADOR INTERMITENTES 27A LAMPARA 12V 21 5W PULSADOR DEL CLAXON FARO INTERMITENTE TRASERO IZQUIERDO 28A LAMPARA INTERMITENTE 12V 10W TRIP MODE PULSADOR DE STOP DELANTERO PULSADOR DE STOP TRASERO SENSOR C Km AJN Engine workshop manual Engine 1 INTRODUCTION 1 1 ENQUIRY NOTES 1 2 UPDATING GUIDE 1 3 WRITING SIMBOLOGY 1 4 OPERATIVE SIMBOLOGY 1 5 WORK GENERAL RULES 1 6 RECOMMENDATIONS 1 7 SPARK PLUGS 1 8 SPARK PLU
7. Rotate the crankshaft anticlockwise aligning the mark a of the rotor with the stationary point b of the chassis cover 1 with the piston in the top dead centre TDC and when the mark of the control gear is aligned with the mark of the cylinder head Measure the set of valves with a calibre of thickness Unspecified gt Set adjustment 4 ADJUST Set of valves Steps for measuring Loosen the locknut 1 Rotate the adjuster 2 towards the inside or outside with the fixed adjustable spanner 3 to obtain the specified play Turn towards the inside Play diminishes Turn towards the outside Play increases Checks and adjustments Vj Install the adjuster to impede it turns and tighten the locknut Locknut 0 8Kgf m 0 8N m Measure the set of valves f the play is incorrect repeat the aforementioned steps until the correct play is achieved 5 INSTALL Top of the point control with the gasket 1 Central cap with the gasket 2 SPARK PLUG CONTROL I REMOVE e Spark plug connector e Spark plug Before removing the spark plug blow on the area with compressed air to eliminate any piece of dirt in order to avoid it falls inside the engine 2 CHECK e Spark plug Type Incorrect gt Replace Standard spark plug CR7HSA NGK U22 FSR U DENSO Checks and adjustments LL Z Q N I 3 CHECK Electrodes 1 Damages Wear gt Repla
8. sufficient clamping force they may also damage the screw head or hexagon Never tap the wrench with hammer or other similar tools to loosen or tighten screws and nuts F 2 Never attempt to increase the lever arm by fitting tube into the wrench F 3 Chassis Never use open flames for any reason Never leave open containers or containers not suitable for holding fuel in passageways close to heat sources etc Never use petrol to clean the vehicle or the floor of the workshop Always use low flash Ak point solvents to clean the vehicle components i Never suck from or blow into the fuel pipe When welding make sure that there are no flammable liquids in the vicinity Always re move the tank even if completely empty and disconnect the negative cable from the battery Never leave the engine running in closed or poorly ventilated areas Before any servicing make sure that the motorbike is perfectly stable A The front wheel should preferably be anchored to the equipment A F 4 integral with the lifting board lo know the motoreycle Rieju chassis Chassis MAINTENANCE OPERATIONS IST SERVICE 2ND SERVICE SERVICE EACH AT 1 000 3 000 km 5 000 km Brake system checking o o Transmission oil level checking Change Change Chain tension and wear inspection o Suspension control o Controls and cables checking
9. 32 32 33 33 33 34 35 35 36 36 3 3 38 39 39 40 41 41 42 42 42 43 43 43 44 44 Chassis 35 36 3f 38 39 40 41 42 REAR FOOTREST REAR BRAKE LEVER DRIVE CHAIN GUARD TRANSMISSION CHAIN REAR BRAKE PUMP KICK STARTER SWING ARM TORQUE 44 45 45 45 46 46 47 47 Introduction Introduction Chassis This workshop manual contains the main electromechanical checks as well as the essential general checks and the fitting of components supplied separately designed to prepare the factory new mo ped for delivery It is very important to adhere strictly to the instructions set out in the manual Interventions carried out superficially or worse still omitted entirely may result in personal injury to the user damage to the machine etc or may simply result in disagreeable complaints N B Rieju S A reserves the right to make changes at any time without prior notification For any enquiry or for further complimentary information please call the Rieju S A After sales Service MANUAL UPDATES Updates will be sent within a reasonable period of time Each new CD Rom will update previous information The contents list will be updated if the modifications and or variations in the pages affect the ability to consult the manual IMPORTANT This series of workshop manuals should be considered as work instruments in the mselves and can only maintain their
10. 4 and negative B F 14 black 8 REAR DIRECTION INDICATORS Cut the clamp that hold the cables A F 15 and disconnect them from the general wiring Following loosen the screw B F 16 and pull the cable to remove the light ATTENTION Before proceeding to the lig hts disassembly pay attention to the sequen ce of the terminals for the later assembly see electric diagram Chassis Rieju chassis Chassis 9 TAILLIGHT Disconnect the terminal A F 17 from the wiring After loosen the 2 screws B F 18 that hold the cover of the taillight To extract it pull the cable C F 19 to remove the light ATTENTION Before proceeding to the lights disassembly pay attention to the sequence of the terminals for the later assembly see electric diagram 10 AIR FILTER Remove the seat and the right lateral cover Unscrew the 3 bolts A F 20 of the filter cover After remove the filter B F 21 Rieju chassis Chassis IIl REGULATOR Remove the seat Disconnect the regulator from the wiring A F 22 Following unscrew the bolt B F 22 to remove it ATTENTION Connect the earth cable again during the assembly 12 COMPONENTES EL CTRICOS Remove the seat Disconnect the intermittence station A F 23 from the general wiring After extract it from the rubber environmental starter relay sensor 13 CDI
11. White red Black cable cable In the event of getting the values of the chart correctly the regulator should be replaced Ignition system Chassis 1 5 IGNITION SYSTEM Ignition diagram SAS TINdWI 40 1109 Magnetic flywheel 2 Ignition Key 3 CDI unit 4 High tension coil 5 Spark plug FAILURE LOCATION If the vehicle doesn t sparkle or the ignition is misfired the following checking should be carried out Firstly the black white wire should be disconnected or connected directly to earth to neutralize the stopping system of the vehicle If the problem persists check each component of the ignition system Before beginning checking the components verify that the connections are clean and well connected and the wiring is in good conditions The resistance control of the components must take place when the engine is cold Ignition system Chassis CHECKING OF THE HIGH TENSION COIL Before beginning the verifications assure that the ground of the high tension coil is co rrect and its fixing is free of rust and clean Resistance of the primary winding Measure the resistance between the terminal and ground 0 30 10 20 C Resistance of the secondary winding Measure the resistance between the high wire and ground 3 16KQ 10 20 C Ignition system Chassis CHECKING OF THE ANTIPARASITIC PIPE Take the spark plug pipe apart rotating it an
12. e Washer Operation lever unit 3 Engine disassembly 3 REMOVE Neuter switch OD O 3 10 CRANKSHAFT I REMOVE Crankshaft 1 with the rocker arm shaft 2 Remark e Remove the crankshaft with the crankshaft extractor 1 e Tighten the screws of the crankshaft extractor till the end but make sure that the body of the tool is in parallel with the chassis If it is necessary loosen one of the screws to adjust the position of the crankshaft extractor Engine disassembly Engine 3 11 ROCKERS CAMSHAFT AND VALVES LL Z Q N I I LOOSEN Locknut of the valve adjusters Valve adjusters 2 REMOVE Clamp plate 1 3 REMOVE e Camshaft 1 e Space washer 2 4 REMOVE Rockers shafts Rockers intake and exhaust Remark e Install the special tool 1 in the rocker shaft to take it out Remark Before removing the internal parts valves springs valve seating etc of the cylinder head check the valves are closed Engine disassembly Engine 5 CHECK Valve closing Leaks in the valve seating gt Check the valve valve seating and width of the val ve seating See section CHECK AND REPAIR VALVE SEATING Steps for checking Fill up the intake chamber and then the exhaust chamber with petrol 1 Check the closing of both valves The valve seating 2 cannot have any leak 6 REMOVE Valve clasp
13. A F 4 of each plate located in the lower part of the plates After pull the part to remove it Rieju chassis IE i Chassis 4 PILLION SEAT Remove the seat Unscrew the 2 bolts A F 5 and remove it by the front 5 MUFFLER Loosen the clamp A F 6 of the exhaust whi ch holds the muffler Following unscrew the bolt B F 7 which holds the muffler on to the chassis To extract it pull the muffler backwards ATTENTION Before proceeding to the mu ffler disassembly make sure that it is cooled down Rieju chassis Chassis 6 EXHAUST Remove the left lateral cover and the left front lateral cover To facilitate the extraction of the exhaust remove the go faster stripes A F 8 Loosen the clamp B F 9 of the exhaust which holds the muffler Remove the 2 bolts C F 10 that hold the exhaust on to the engine in the front part Remove the bolt D F I1 that holds the exhaust in the front part of the motorcycle To remove the exhaust from its position Pull it to be able to extract it from the engine and from the clamp of the muffler Place the exhaust in parallel with the chassis E F 12 and after turn it F F 13 and pull to remove it from its position ATTENTION Before proceeding to the muffler disassembly make sure that it is cooled down Rieju chassis 7 BATTERY Remove the seat Disconnect the two cables positive red A F
14. Screws chassis V 82 25 83 45 mm jJ Remark Press the screws in numerical decreasing order see the numbers in the figure Engine assembly and adjustments 5 APPLY Oil motor 4T in the elbows of the crankshaft ball bearings orifices of oil supply 6 CHECK Operation of the crankshaft and the transmission Irregular operation gt Repair Engine assembly and adjustments Engine 3 42 CHANGE SHAFT AND START SYSTEM WITH PEDAL 5 0 Kgf m 50 N m I Change shaft 2 Torque spring 3 Constrained rod 4 Return spring 5 Segment 6 Start system unit 7 Clamp ring 8 Washer 9 Start gear 10 Washer I1 Clamp ring LL Z Q N I Xi Engine assembly and adjustments Engine 3 43 CHANGE SELECTOR SEGMENT AND CHANGE SHAFT I INSTALL Tang guide 1 in the supporter 2 2 INSTALL e Segment 1 Using an Allen spanner of 4 mm Remark Install the tang guide of the segment in the positioning orifice a of the change selec tor and install the segment So 3 INSTALL Rod limiter 1 Spring 2 Remark Couple the spring on the rod limiter 1 and in chassis drum Couple the rod limiter 1 on the limiter of the change selector Screw Rod limiter 1 0 Kgf m 10 N m 4 INSTALL Change shaft unit 3 Remark Apply grease on the tangs of the constrained rings Fit the tips of the spring into the
15. place Keep your workplace duly clean and tidy To tighten bolts and nuts begin with those of bigger diameter or the interior ones proceeding in cross in one go and so on T he most proper use of the spanner the fork one is in one go never pushing The rolling monkey wrench 1 have to be used in emergency conditions this is to say when the suitable size tool is not available During the effort the mobile clamp tend to open and this could damage the bolt as well as lead to obtain a torsion moment of an unreliable tightness Anyway use tools like the illustration figure 1 Excluding some exceptional assistance cases prepare a record card for the Customers where all the interventions done and notes for possible controls in future will be entered Introduction Engine 1 6 RECOMMENDATIONS Before beginning any intervention in the motor vehicle wait till all and each one of the components of the same vehicle are completely cool down If the operations need two technicians work it is necessary that they previously come to an agreement on tasks and synergies Always check the correct assembly of each component before assemble another one Lubricate the need spare parts before re assembly The linings the watertight and elastic rings and the pins must be replaced when disassembly takes place The torque values indicated in the manuals refer to the final tight and the
16. Magneto rotor 10 Stator Il Gasket 12 Tang guide 13 Chassis cowling Engine assembly and adjustments 3 50 START GEAR CHECKING 1 INSPECT Teeth of the start gear system a b c Rims filings roughness wear gt Replace 2 CHECK Operation of the start clutch Push the tang guide following the indicator Stiff operation gt Replace Steps for checking Loose the start clutch When rotating the start gear the big one clockwise A the start clutch and the start gear should be coupled On the contrary the start clutch is damaged Replace When rotating the start gear anticlockwise B it should turn freely On the contrary the start clutch is damaged Replace 3 51 MAGNETO ROTOR AND STAR GEAR I INSTALL Timing chain Guide of the chain Screw guide of the chain J 1 0 Kgf m 10 N m Remark Fasten a wire on the timing chain to avoid this falls inside the chassis Engine assembly and adjustments 2 INSTALL e Start gear 1 Plate 2 J Screw of the plate n 0 7 Kgf m 7 N m 3 INSTALL Motor Oil 4T in the start gears 4 INSTALL Washer 1 e Start gear 2 SJINSTALL Cotter Magneto rotor Remark Install the rotor provisionally aligning the groove of the cotter with the cotter Rotate the start gear clockwise and install the rotor in the start gear Engine assembly and adjustments
17. adjustment and grease e o o Wheel spoke tension and wheel off centre inspection e e Air filter cleaning and grease o o Carburettor checking adjustment e Spark plug checking and adjustment or change e Screws and chassis nut control plastics e e Electrical system checking Segments wear control o Exhaust system checking Terminals and battery conditions checking SPECIFICATIONS AND TECHNICAL CHARACTERISTICS Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Weight Dry Engine Type Transmission Make Cylinder arrangement Cylinder capacity Bore x stroke Compression ratio Starting system type Lubrication system 1995 mm 800 mm 1130 mm 790 mm 1305 mm 250 mm 4 stroke SOHC 5 speeds YAMAHA Monocylindrical forward inclined cylinder 123 7 54 x 54 mm 10 1 Kick starter and electric starter Wet sump Rieju chassis Transmission Oil Type Quantity Air Filter Fuel Type Fuel tank capacity Carburettor Spark plug Type Electrodes gap Clutch type Primary transmission Clutch crown Stroke pinion Transmission ratio Secondary transmission Start engine pinion Pulling plate Transmission ratio Chain Primary shaft 9 9 4 Z 14 Z 48 bee GEAR CHANGE Secondary shaft Unleaded petrol Mikuni VM 20 Wet multiple disc 428 RN8 x 126 steps G
18. are on the right sump Vehicle identification number The identification number of the motorcycle B F 2 is stamped on the steering pipe SAFETY TAG 5000 asgi i 1 MIRUMNHT VM 20 L amp amp La i f It contains the identification data of the mo torcycle according to the 97 24 CE guidelines el 1 00000000 E 0 0008702000 It is absolutely essential to indicate the identi fication data of the motorcycle when ordering spare parts This tag should not be substituted either mo dified Rieiu chassi ieju chassis Chassis IDENTIFICATION OF THE MAIN PARTS Left side 2 3 Headlight Rear view mirror Fuel tank Battery Rear direct indicators Side stand Gear pedal Front direct indicators O M O UI d UN IDENTIFICATION OF THE MAIN PARTS Right side 9 Grab bar 10 Air filter box 11 Fuel tank cap 12 Rear brake pedal 13 Passenger footrest 14 Number plate light and plate holder Rieju chassis Chassis CONTROLS AND INSTRUMENTS Pas f f r m D y z f a y E tot al d y i a4 03 2 a Q0 F 6 1 Rear view 7 Accelerator grip 12 Indicator switch 2 Clutch lever 8 Start switch 13 Start lever 3 Dashboard 9 Fuel tank cap 14 Horn switch 4 Main switch 10 Stop switch 5 Front brake pump Il Lights switch dipp
19. be used as the movable jaw tends to open thus risking damaging or not properly tightening the bolt to the correct torque In any case when using an adjustable wrench take care to proceed as shown in Figure l e Except for occasional customers always make out and deliver to the customer a work sheet specifying the operations performed with notes as to any future checks eventually required Introduction Chassis RECOMMENDATIONS Before carrying out any operation on the vehicle wait for all parts to cool down For operations requiring two mechanics make sure that the various steps to be performed by each of them are clearly defined and coordinated beforehand Make sure that each component has been properly fitted before proceeding with the next one Lubricate all parts where applicable before reinstalling them Gaskets O rings circlips and split pins must be replaced at every refitting The torque settings specified in the manuals refer to the final torque which must be attai ned progressively by steps Loosen and tighten aluminium alloy parts covers only after the engine has fully cooled down Only use screwdrivers with sizes suitable to the screws to be loosened or tightened Work in comfortable position and ensure that the vehicle is stable Never use screwdriver as lever or chisel Never use pincers to loosen or tighten screws or nuts because in addition to not providing
20. cavity by the right side Rieju chassis bat i Chassis 22 FRONT DIRECTION INDICATORS Disconnect the light from the general wiring A F 38 After unscrew the bolt B F 39 ATTENTION Pay attention to the position of the cables for the later assembly 23 HEADLIGHT To facilitate the task unscrew the 3 bolts of the fuel tank and push it aside to gain access to the headlight connection Disconnect the terminal of the headlight from the wiring A F 40 After unscrew the 2 bolts B F 41 which hold the headlight ANI ATTENTION Pay attention to the cable position for the later assembly N Rieju chassis Chassis 24 DASHBOARD To make the task easier put the fuel tank and the headlight aside to gain access to the odometer connections Disconnect the 2 terminals of the odometer A F 42 and the other both of the front part B F43 Following unscrew the 2 top bolts C F 44 that hold the screen on to the chassis Rieju chassis Chassis 25 FRONT BRAKE PUMP Disconnect the micro switch terminals of the brake light A F 45 Unscrew the join B F 45 that holds the tube on to the pump After unscrew the 2 bolts C F 46 and remove the front brake pump N ATTENTION For the later assembly it is advisable to replace the copper gaskets and drain the circuit ATTENTION Brake Liquid is abrasive 26 CLUTCH LEVER Disconnect the tr
21. gear start gear 1 Teeth of the gear ratchet brace 2 LL Z Q N I Damages wear gt Replace 2 MEASURE Friction force of the ring of the start gear torque spring 1 Unspecified gt Replace Use dynamometer 2 8 Friction force of the ring of the start system n 0 8 1 2 K f 3 29 OIL PUMP CHECKING I MEASURE Play among tips TO between internal rotor 1 and external rotor 2 Lateral play B between external rotor 2 and the pump casing 3 Unspecified Replace the oil pump unit Play between the casing and the rotor C between the pump casing 3 and the rotors 1 and 2 Unspecified Replace the pump oil unit Check and repairs Play among tips A Vi 0 15 mm lt Limit 0 20 mm gt Lateral play B 0 06 0 10 mm lt Limit 0 15 mm gt Play between the casing and the rotor C 0 06 0 10 mm lt Limit 0 15 mm gt 2 CHECK Rotary filter Cracks damages gt Replace Contamination gt Clean 3 CHECK Oil impeller Cracks damages gt Replace Contamination gt Clean 3 30 OIL LEAKS CHECKING COVER OF THE CASSING IN THE RIGHT SIDE 1 CHECK Oil leak Obstruction gt Blow with compressed air Check and repairs Engine 3 31 CHASSIS I Wash the chassis properly with kerosene 2 Clean the surfaces which bear the gaskets and the surfaces in contac
22. is good first it should be charged according to the aforementioned standard method Next leave the battery at rest during hour and take the measurements according to this chart VOLTAGE IN TERMINALS BATTERY CONDITION 12 5 V or more Good battery Between 12 V and 12 5 V Standard recharge Less I2 V Change the battery Recharge system and lights Chassis LL Z Q I 1 4 RECHARGE SYSTEM AND LIGHTS Diagram of the charge circuit and lights supply B BL Yellow alternates WIR lig hts R Alternator 2 Regulator AC AD 3 Battery 4 Fuse FAILURE LOCATION To control if the charge and outlet system work correctly check the voltage with the tester Outlet data of the regulator The battery voltage red and black cable should be between 13 8V to 14 8 with the vehicle running at 4000 R P M tester in direct current The voltage of alternating yellow and black cable should be between 13 8V to 14 5V at 4000 R P M tester in alternating position The voltage of alternating white cable red and black cable should be between 13 8V to 14 5V at 4000 R P M tester in alternating position If the previous parameters are not fulfilled check the alternator Check of the alternator It should be made with the 4 ways connector of the unplugged magnetic flywheel and with the engine in cold TESTER SCALE TESTER CONNECTIONS READING Red clip Black clip
23. limiter 4 Engine assembly and adjustments Engine 3 44 START SYSTEM WITH PEDAL INSTALLATION I INSTALL Unit of the start system shaft 1 Clamp ring of the start gear 2 Remark Rotate the torque spring clockwise and couple it into the chassis orifice a 2 INSTALL Clamp ring 1 Washer 2 e Start gear 3 Washer 4 Clamp ring 5 Engine assembly and adjustments 3 45 CLUTCH HOOD AND OIL PUMP 0 6 Kgf m 6 N m 6 0 Kgf m 60 N m 0 8 Kgf m 8 N m 1 0 Kgf m 70 N m Ot Qu I Clutch spring 16 Drive gear of the oil pump 2 Pressure plate 17 Driven gear of the oil pump 3 Operation plate 18 Oil pump 4 Operation rod 19 Gasket 5 Friction plate 6 Separator 7 Clutch drum 8 Pressure washer 9 Clutch hood 10 Ball Il Operation rod 2 12 Shaft of the operation lever 13 Primary gear 14 Rotary filter 15 Cotter Engine assembly and adjustments 3 46 OIL PUMP INSTALLATION I LUBRICATE Leak of oil supply chassis RS Oil pump unit I Recommended Lubricant Motor oil 2 INSTALL Drive gear of the oil pump Cotter Remark I Assemble the gear of the oil pump with the pipe towards inside 2 Assemble the rotary filter with the side of the larger salient towards inside fitting the fluke in the pipe of the crankshaft 3 47 CLUTCH HOOD INSTALLATION I INSTALL Primary gear 1
24. point a is inside the band b in the magneto flywheel Outside the band gt Check the ignition system Remark e The ignition point is not adjustable 4 INSTALL Top of the point control with the gasket 2 5 COMPRESSION PRESSURE ADJUSTMENT Remark Insufficient compression pressure results in loss of power I CHECK Set of valves Unspecified gt Adjust See section VALVES SET ADJUSTMENT 2 Get the engine started and let it warming up for some minutes 3 Pull the engine up Checks and adjustments Engine 4 REMOVE e Spark plug Before removing the spark plug blow on the area with compressed air to A eliminate any piece of dirt in order to avoid it falls inside the engine 5 INSTALL Compressor gauge 1 6 MEASURE Compression Pressure If it exceeds the permitted maximum pressure gt the cylinder head the valves surface and the piston head in relation to carbon If it is under the minimum pressure gt Inject some drops of oil into the cylinder and measure again Follow the table below COMPRESSION PRESSURE With oil injected into the cylinder Higher measure than without oil Worn or damaged piston The same measure as without oil Possible defect in rings valves cylinder head gasket or piston REPAIR Compression pressure at the sea level amp 2 Standard 1 200 12 Kg cm 1 Minimum 1 040 KPa 10 4 Kg cm LL Z
25. resistance To check if the thermal resistance works correctly you should supply of a battery at I2V and in a few seconds it should warm up Dashboard programming Chassis 1 10 DASHBOARD PROGRAMMING DASHBOARD The insertion of Values in the Display is carried out through the button Trip placed in the left side of the Handlebar In the Model TANGO the Battery is connected and loaded so it can be carried out with the key in the ignition position and also with the engine running INSERTION OF THE VALUES OF CALCULATION IN THE ODOMETER MEMORY Development of the wheel that sets the signal sensor Pulses of the signal sensor Pulses of Revolutions Put the key in the ignition position and start the engine Wait some seconds till the INITIAL screen appears on the DISPLAY Press the button TRIP for 6 seconds and the Screen will show the digits to insert the value of the development of the wheel the flickering digits are the selected ones following the sequence of pressing the button we will choose the number and keeping the button pressed for 3 seconds we will pass to the next digit and so forth until set the value Dashboard programming Chassis Pressing the button TRIP for 3 seconds we will pass to the next screen of the Display where the word PULSE will appear following the sequence pressing the button TRIP we will insert the value corresponding to the pul
26. sump 4 INSTALL Drainage cap 1 Oil level dipstick Drainage cap 2 0 Kgf m 20 N m LL Z Q I Checks and adjustments 5 SUPPLY Oil in the sump Quantity of oil LOL 6 CHECK Level of motor oil See section CHECKING THE LEVEL OF MOTOR OIL OIL FLOW CHECKING 2 9 OIL FLOW CHECKING I REMOVE Control screw of the oil flow 1 2 Get the engine started and keep it in the idling speed till the oil drips from the drain orifice Oil flows gt Oil pressure is good Oil doesn t flow gt Oil pressure isn t not good If oil doesn t come out after some seconds Pull the engine up immediately and Check the oil pump section 3 TIGHTEN Control screw of the oil flow Screw of the oil flow 0 7 Kgf m 7N m Checks and adjustments Engine 2 10 EXHAUST SYSTEM CHECKING 1 CHECK Screws 1 exhaust pipe Loose damages gt Tighten I replace Gasket exhaust pipe Leak of exhaust fumes gt Tighten replace Screw 0 7 Kgf m 7N m 2 CHECK e Screws 2 Loose damages gt Tighten I replace Screw 1 5 Kgf m ISN m Engine RIEJU Engine disassembly Engine LL Z Q N I 3 1 MOTOR DISASSEMBLY CYLINDER HEAD CYLINDER AND PISTON REMARK With the assembled motor in the frame the cylinder head camshaft and cylinder can be checked replace the follow
27. value over time if they are kept constantly up to date Chassis SYMBOLOGY USED INTHE MANUAL CAUTION Recommendations precautions regarding rider safety and mo tor vehicle integrity WARNING Situations entailing the risk of personal injury to maintenance or repair mecha nics other workshop personnel or third parties or damage to environment vehicle or equipment FIRE HAZARD Indicates operations which may constitute a fire hazard RISK OF EXPLOSION Indicates operations which may constitute a risk of explosion TOXIC Indicates a possibility of intoxication or inflammation of the upper respiratory A tract 5 MECHANICAL MAINTENANCE Operations to be performed only by an expert mechanic ELECTRICAL MAINTENANCE Operations be performed only by an expert electrical electronic technician NO Operations to be absolutely avoided SERVICE MANUAL Indicates information which may be obtained by referring to said manual SPARE PARTS CATALOGUE Indicates information which may be obtained by referring to said catalogue Introduction Chassis ABBREVIATIONS USED INTHE MANUAL Figure Tightening torque Paragraph Note The letter Tr in the illustrations refers to retaining or adjusting screws The number following this letter refers to the number of the same type of screw in the unit or com
28. valve 2 Special gasket 3 Damages wear obstruction gt Replace the unit 7 L4 4 INSPECT Needle of the lock valve 1 Diffuser 2 High spout 3 Low spout 4 Pilot screw of air 5 Warping wear damages gt Replace Obstruction gt Blow the spouts with compressed air A Se Carburettor Engine HSIIONSA 5 CONTROL Free movement Place the lock valve in the body of the carburettor and control if this moves freely Obstruction gt Replace 3 59 ASSEMBLY Invert the procedure of DISASSEMBLY Pay attention to the following points Before the assembly wash all the parts with kerosene Always use new gaskets I INSTALL Low spout 1 Pilot screw unit of air 2 2 INSTALL Special gasket New Diffuser 1 High spout 2 Carburettor Engine 3 INSTALL Seating of the needle valve 1 Needle valve 2 4 INSTALL Float 1 Tang of float 2 5 MEASURE Height of the float a without the gasket Incorrect gt Adjust JA V Height of the float J d 18 9 mm 6 INSTALL Gasket of the carburettor tank 1 New Carburettor tank 2 HSIIONSA Carburettor Yi 3 60 FUEL LEVEL ADJUSTMENT I MEASURE Level of fuel a Unspecified gt Adjust Level of fuel 6 7 mm under the line of the tank Steps for ad
29. 1 Remark Install the valve spring compressor 2 between the seating of the clasp and the cylinder head to loosen the valve clasp Engine disassembly 7 REMOVE Clasp seating 1 Spring 2 Valve 3 Constraint ring 4 Spring seating 5 Remark e Identify the position of each piece carefully so that they can be reinstalled in their original positions 3 12 CYLINDER HEAD CHECK AND REPAIR I ELIMINATE Carbon sediment of the compression chamber Use rounded spatula Remark Do not use an instrument with sharp edges to avoid damages and scratches e In the thread of the spark plug n the valve seating Check and repairs 2 CHECK Cylinder head Scratches damages gt Replace 3 MEASURE Strain Unspecified gt Rectify Strain of the cylinder head Below 0 03 mm Steps for measuring the strain and correction e Place a rule 1 and a calibre of thickness 2 on the surface of the cylinder head as it is illustrated above Measure the strain f the strain is unspecified correct the cylinder head Put a sandpaper of 400 600 on a flat surface and correct the cylinder head surface with 8 shaped movements Remark Rotate the cylinder head several t mes to avoid excessive removal of material only in one side HSIIONSA Check and repairs 3 13 VALVE SEATING I ELIMINATE
30. AJN Chassis workshop manual Chassis INTRODUCTION MANUAL UPDATES SYMBOLOGY USED IN THE MANUAL ABBREVIATIONS USED IN THE MANUAL GENERAL WORK RULES RECOMMENDATIONS O o N O TO KNOW THE MOTORCYCLE MAINTENANCE OPERATIONS SPECIFICATIONS AND TECHNICAL CHARACTERISTICS UNPACKING AESTHETIC CONTROL IDENTIFICATION DATA SAFETY TAG IDENTIFICATION OF THE MAIN PARTS CONTROLS AND INSTRUMENTS KEYS STEERING LOCK SIDE STAND DASHBOARD TYRES PRESSURE CONTROL FUEL TANK TRANSMISSION OIL BRAKE OIL ADJUSTMENT OF THE MINIMAL INTERVAL OF TURN TENSION ADJUSTMENT OF THE TRANSMISSION CHAIN 14 14 18 18 Chassis DISASSEMBLY N O 7 OQ N gt W NB NY NB NO NB NY MN MN MN YN gt a gt gt AA N gt O O WAN O Ci HV gt O 0 WAN DO A O N gt SEAT LATERAL COVER FRONT LATERAL COVER PILLION SEAT MUFFLER EXHAUST BATTERY REAR DIRECTION INDICATORS TAILLIGHT AIR FILTER REGULATOR COMPONENTES EL CTRICOS CDI UNIT FILTER BOX SHOCK ABSORBER GEAR LEVER FUEL TANK CARBURETTOR SIDE STAND FRONT MUDGUARDS ENGINE FRONT DIRECTION INDICATORS HEADLIGHT DASHBOARD FRONT BRAKE PUMP CLUTCH LEVER HANDLEBAR FRONT BRAKE PIN REAR BRAKE PIN FRONT WHEEL ODOMETER SENSOR FRONT BRAKE DISC STEERING FRONT FOOTREST 28 28 28 29 29 30 31 31
31. CKING 3 35 ROCKERS AND CAMSHAFT INSTALLATION 40 40 41 42 43 44 46 48 50 52 53 54 55 55 57 58 59 60 61 61 63 64 66 66 67 68 68 69 70 72 Engine 3 36 CRANKSHAFT AND ROCKER ARM SHAFT 74 3 37 CHANGE SELECTOR 76 3 38 TRANSMISSION FORKS AND CHANGE SELECTOR INSTALLATION 77 3 39 TRANSMISSION 78 3 40 CHASSIS 80 3 41 CHASSSIS RIGHT SIDE 81 3 42 CHANGE SHAFT AND START SYSTEM WITH PEDAL 83 3 43 CHANGE SELECTOR SEGMENT AND CHANGE SHAFT 84 3 44 START SYSTEM WITH PEDAL INSTALLATION 85 3 45 CLUTCH HOOD AND OIL PUMP 86 3 46 OIL PUMP INSTALLATION 87 3 47 CLUTCH HOOD INSTALLATION 87 3 48 CLUTCH INSTALLATION 88 3 49 MAGNETO FLYWHEEL 92 3 50 START GEAR CHECKING 93 3 51 MAGNETO ROTOR AND START GEAR 93 3 52 CYLINDER AND PISTON 96 3 53 CONTROL GEAR AND TIMING CHAIN 97 3 54 RINGS PISTON AND CYLINDERS INSTALLATION 98 3 55 CYLINDER HEAD INSTALLATION 100 3 56 CARBURETTOR 104 3 57 DISASSEMBLY 105 3 58 CHECKING 106 3 59 ASSEMBLY 108 3 60 FUEL LEVEL ADJUSTMENT 110 Introduction Introduction Engine l ENQUIRY NOTES The intervention in control maintenance repairs replacement parts etc in the whole range of our motor vehicle means not only the competence and experience of the responsible technicians in this task in the modern technologies but also the knowledge of the quick and rational procedures of the technical characteristics of the calibrated values of the torque that only manufactur
32. G MAINTENANCE 1 9 SPARK PLUG REPLACEMENT 1 10 MOTOR REMOVAL 1 11 MOTOR DISASSEMBLY Oo N D 12 13 13 13 13 2 GENERAL SPECIFICATIONS 2 1 TORQUE GENERAL SPECIFICATIONS 2 2 LUBRICATION DIAGRAM 2 3 VALVES SET ADJUSTMENT 2 4 IGNITION POINT CONTROL 2 5 COMPRESSION PRESSURE ADJUSTMENT 2 6 CHECKING OF THE MOTOR OIL LEVEL 2 7 RECOMMENDED MOTOR OIL 2 8 MOTOR OIL CHANGE 2 9 OIL FLOW CHECKING 2 10 EXHAUST SYSTEM CHECKING 14 19 17 21 22 24 24 25 26 27 3 1 MOTOR DISASSEMBLY 3 2 MAGNETO FLYWHEE 3 3 CLUTCH 3 4 PUMP OIL 3 5 START PEDAL SHAFT 30 33 35 38 39 3 6 DISASSEMBLY OF THE START SYSTEM SHAFT WITH PEDAL 3 7 CHANGE SHAFT 3 8 CHASSIS 3 9 ROCKER ARM TRANSMISSION AND CHANGE SELECTOR 3 10 CRANKSHAFT 3 11 ROCKERS CAMSHAFT AND VALVES 3 12 CYLINDER HEAD CHECK AND REPAIR 3 13 VALVE SEATINGS 3 14 VALVES AND VALVE SPRINGS 3 15 CAMSHAFT CHECKING 3 16 ROCKERS AND THEIR SHAFTS CHECKING 3 17 CAMSHAFT CHECKING 3 18 TIMING CHAIN STRUT 3 19 CYLINDER AND PISTON 3 20 RINGS CHECKING 3 21 BOLT CHECKING 3 22 CRANKSHAFT 3 23 ROCKER ARM CHECKING 3 24 CLUTCH HOOD CHECKING 3 25 CLUTCH CHECKING 3 26 ROD OPERATION CHECKING 3 27 FORKS AND CHANGE SELECTOR CHECKING 3 28 START SYSTEM WITH PEDAL CHECKING 3 29 OIL PUMP CHECKING 3 30 OIL LEADS CHECKING 3 31 CHASSIS 3 32 CLAMP RINGS AND WASHERS 3 33 MOTOR ASSEMBLY AND ADJUSTMENTS 3 34 VALVES AND VALVE SPRINGS CHE
33. Q I Checks and adjustments Engine Steps for measuring Get the engine started with the throttle totally opened until the compression reading becomes stabilized Before getting the engine up connect the cable from the spark plug to earth to avoid sparks 7 INSTALL e Spark plug 2 6 CHECKING OF THE MOTOR OIL LEVEL I Place the motorcycle in a flat surface Remark e Make sure that the motorcycle is in vertical line when checking the oil level 2 Get the engine started and let it warming up for some minutes 3 Pull the engine up 4 Move the oil level dipstick 1 Clean it with a cloth and place it in the orifice of oil supply without threading it Immediately move it again 5 CHECK Level of motor oil The level of oil should be between the maximum 1 and minimum 2 marks Oil underneath the minimum level gt Add oil up to the appropriate level 2 7 RECOMMENDED MOTOR OIL Recommended motor oil YAMALUBE 4 or similar Checks and adjustments Engine 6 Get the engine started and let it warming up for some minutes 7 Pull the engine up Remark Wait some minutes till the oil goes down before checking the oil level 2 8 MOTOR OIL CHANGE I Get the engine started and let it warming up for some minutes 2 Pull the engine up and place tray under the motor 3 REMOVE Oil level dipstick Drainage cap 1 Gasket Drain the oil in the
34. UNIT Remove the left front lateral cover Disconnect the CDI unit A F 24 from the general wiring Following extract it from the rubber Rieju chassis Chassis 14 FILTER BOX Remove the seat the fuel tank and the muffler To make the task easier unscrew the 2 bolts A F 24 of the rear chassis and loosen the precedent 2 B F 24 Loosen the nozzle C F 25 of the carburettor and the ventilation tube D F 25 After unscrew the 4 bolts E F 26 at the top To extract it lift the rear chassis and remove the filter box Rieju chassis lis i Chassis 15 SHOCK ABSORBER Remove the seat and the filter box To make the task easier unscrew the 2 bolts A F 27 of the rear chassis and loosen the precedent 2 B F 27 Unscrew the 2 bolts A F 28 that hold the shock absorber on to the chassis and remove it from the back ATTENTION Before disassembly hold the chassis by the lower part in order to avoid the fall of the swing arm and the wheel ATTENTION Pay attention to the shock absorber position for the later assembly 16 GEAR LEVER Unscrew the fixing A F 29 bolt Following pull carefully the lever in order not to damage the grooved shaft Rieju chassis Chassis 17 FUEL TANK Remove the seat ATTENTION before proceeding to the di sassembly turn off the tap of the tank Remove the clamp of the tap A F 30 afte
35. ace the crankshaft and or ball bearings Remark e Measure the non alignment crankshaft Rotate the crankshaft unit slowly 2 Non alignment limit il 0 03 mm 2 MEASURE Lateral play of the connecting rod Unspecified gt Replace the connecting rod ball bearing the crankshaft elbow and or the connecting rod JF Lateral play of the connecting rod n 0 15 0 45 mm 3 MEASURE Width of the crankshaft Unspecified gt Replace the crankshaft J F Width of the crankshaft jl 46 95 47 00 mm Check and repairs Sa Engine 4 CHECK Crankshaft gear 1 Damages wear gt Replace the crankshaft LL Z Q N I Ball bearing 2 Wear fissures damages gt Replace the crankshaft 5 CONTROL Oil leak in the crankshaft Obstruction gt Compressed air blowing 3 23 ROCKER ARM CHECKING 1 CHECK Teeth of the rocker arm drive gear 1 Teeth of the rocker arm driven gear 2 Wear damages gt Replace the unit 2 CHECK Rocker arm shaft Wear crack damages gt Replace Check and repairs 3 24 CLUTCH HOOD CHECKING 1 CHECK Teeth of the primary gear 1 Teeth of the hood gear 2 Wear damages gt Replace both gears Excessive noise during the operation gt Replace both gears 3 25 CLUTCH CHECKING 1 CHECK Friction plates Wear damages gt Replace the friction plates unit 2 MEASURE Th
36. ain the specified torque A Distances among the planes B External Diameter of the thread Torque general specifications General specifications 2 2 LUBRICATION DIAGRAM Rocker Rocker Intake Exhaust Rocker shaft Pull clutch amsha Chassis LS Centrifugal filter Nec Oil pump Oil in the sump Cil impeller Don t damage the chassis surface otherwise there will be oil leaks General specifications Engine Camshaft Cylinder head Cylinder Chassis cowling LS Centrifugal filter Clutch For a better performance use always oil and amalibe Checks and adjustments 2 3 VALVES SET ADJUSTMENT Remark The valves set should be adjust when the motor is cool down and at room tempe rature When adjusting or measuring the valves set the piston should be in the top dead centre TDC at the compression moment Engine I REMOVE e Spark plug e Screws 1 Lateral cover of the cylinder head 2 Valves lining intake 3 Valves lining exhaust 4 2 REMOVE Top of the point control with the gasket 1 Central cap with the gasket 2 3 MEASURE Set of valves Unspecified gt Adjustment Set of valves cold Intake 0 08 0 12 mm Exhaust 0 10 0 14 mm LL Z Q I Checks and adjustments Engine Steps for measuring
37. ansmission from the clutch A F 47 and from the starter B F 47 After unscrew the 2 bolts C F 47 and re move the lever Rieju chassis Chassis 27 HANDLEBAR Remove the controls from each end Unscrew the 4 bolts A F 48 and remove the handlebar 28 FRONT BRAKE PIN Unscrew the join through the screw A F 49 Following unscrew the 2 bolts B F 49 that hold the pin on to the pin support c ATTENTION For the later assembly it is advisable to replace the copper gaskets drain the circuit Al ATTENTION Brake liquid is abrasive 29 REAR BRAKE PIN Unscrew the join through the screw A F 50 Following unscrew the 2 bolts B F 50 that hold the pin on to the pin support ATTENTION For the later assembly it is advisable to ce The copper gaskets and drain the circuit ATTENTION Brake liquid is abrasive Rieju chassis Chassis 30 FRONT WHEEL ATTENTION Loosen the fixing bolt A F 51 of the axle located at the fork Unscrew the axle of the wheel and remove it 31 ODOMETER SENSOR Remove the headlight Disconnect the sensor A F 52 from the wiring and remove the screw that holds it on to the support 32 FRONT BRAKE DISC Remove the front wheel Unscrew the bolts A F 54 that hold the disc A Rieju chassis baba Chassis 33 STEERING Unscrew the 4 bolts A F 55 o
38. ark Apply motor oil on the bolt This mark gt in the piston should be towards the exhaust side Before installing the clamp bolt cover the opening of the chassis with a clean cloth 3 TO INSTALL Tan guide 1 Gasket of the cylinder New 2 Engine assembly and adjustments 4 POSITION Rings 1 Remark Position the tips of rings in accordance with the figure a Top ring b Oil ring bottom c Oil ring top e d Secondary ring 5 LUBRICATE External surface of the piston Rings Internal Surface of the cylinder 6 INSTALL e Special gasket New e Cylinder 1 Remark Install the cylinder with one of the hands while compressing the rings with the other one Goes the guide of the timing chain exhaust side to the cavity of the timing chain a Orme E No m E Engine assembly and adjustments HSIIONSA 3 55 CYLINDER HEAD INSTALLATION I INSTALL Tang guide New 1 Cylinder head gasket New 2 Guides of the timing chain exhaust 3 2 INSTALL Cylinder head e Screw with washer cylinder head Screws cylinder head M8 1 4 J 2 2Kgf m 22 N m M6 5 6 1 0 Kgf m 10 N m Remark Apply motor oil on the threads of the screws e Press the screws in increasing order 3 INSTALL e Control gear e Timing Chain Steps for the installation e Rotate the crankshaft anticlockwise
39. arping wear damages gt Replace 2 CHECK Grooves in the change selector Wear damages scratches gt Replace Extension of the change selector Wear damages gt Replace CHECK Change fork I in the right centre 1 Change fork 2 in the top left 2 Change fork 3 in the bottom left 3 Guide bar 4 Change selector 5 Tang guide 6 Roll the guide bar ona flat surface Warping gt Replace Do not try to straighten warping guide bar Engine Check and repairs 4 CHECK Movement of the change forks in the guide bar Irregular movement gt Replace the fork and the bar Remark e Ifthe change fork and the transmission gear are damaged replace the gears which are side by side of the unit 5 MEASURE Warping of the Shafts driver and driven one Use a tip support and clock to compare 1 Unspecified gt Replace the warped shaft 6 CHECK Teeth of the gears Blue coloration grooves wear gt Replace Nails of the gears Rounded brim cracks missing parts gt Replace 7 CHECK Change shaft 1 Damages warping wear gt Replace e Spring of return change shaft 2 e Spring of return constrained rod 3 Wear damages gt Replace Check and repairs a Engine 3 28 START SYSTEM WITH PEDAL CHECKING 1 3 28 START SYSTEM WITH PEDAL CHECKING e Teeth of the
40. ate 1 Compression springs 2 e Screws 3 Screws Clutch spring 0 6 Kgf m 6 N m Remark Press the screws of the springs gradually and diagonally Engine assembly and adjustments Engine LL Z Q N I 8 CHECK Position of the operation lever Push the lever unit following the indicator and make sure that the alignment marks are aligned a Marks of the lever b Mark of the chassis 9 ADJUST Position of the operation lever Steps for the adjustment Loose the locknut 1 Rotate the adjuster 2 clockwise or anticlockwise to align the marks Hold the adjuster to avoid its movement and press the locknut Be careful not to press the adjuster 2 excessively since the play between ope ration rods can be eliminated Press the locknut 1 J Locknut n 0 8 Kgf m 8 N m Engine assembly and adjustments X 10 INSTALL ang guide Gasket of the chassis New Chassis cover RS Screws of the chassis cover 1 0 Kgf m 10 N m Remark Press the screws in decreasing numerical order see the numbers in the figure II INSTALL Start pedal Nut of the start pedal 5 0 Kgf m 50 N m Engine assembly and adjustments 3 49 MAGNETO FLYWHEEL 1 0 Kgf m 10 N m I Timing chain 2 Guide of the chain intake 3 Tang guide 4 Start gear I 5 Plate 6 Washer 7 Start gear 2 8 Cotter 9
41. b smaller passage Engine assembly and adjustments Inlet Mark IN Exhaust Mark 4 INSTALL Valve clamp 1 Remark Install the valve clamp while the spring valve is compressed with the compressor of the valve spring 2 5 Fix the clamp valves in the rod pound lightly with rubber hammer Do not hit because valve damaged Engine assembly and adjustments Engine 3 35 ROCKERS AND CAMSHAFT INSTALLATION I LUBRICATE Camshaft 1 Camshaft Oil of disulphide molybdenum Ball bearing of the camshaft Motor oil 2 APPLY e Oil of disulphide molybdenum in the rocker and its shaft am al Oil of disulphide molybdenum 3 INSTALL Rocker Rocker shaft 1 Remark Install completely the shaft of the rocker exhaust Engine assembly and adjustments 4 INSTALL Clamp plate 1 Screw 2 2 Screw clamp plate 1 0 Kgf m 10 N m Engine assembly and adjustments Engine 3 36 CRANKSHAFT AND ROCKER ARM SHAFT I Elbow of the crankshaft 2 Crankshaft 3 Connecting rod 4 Lower ball bearing of the connecting rod 5 Ball bearing of the crankshaft 6 Cotter 7 Rocker arm 8 Ball bearing Engine assembly and adjustments I INSTALL Extractor of the crankshaft 2 INSTALL Crankshaft Remark Hold the connecting rod with one hand while the nut of the special tool tu
42. bled motor in the frame To be able to do it take the following parts out e Exhaust Foot rest e Change pedal e Clutch e Start system with pedal unit 1 REMOVE Change shaft 1 Torque spring 2 Screw constrained rod 3 Constrained rod 4 Engine disassembly Engine 3 8 CHASSIS 1 REMOVE Screws chassis Battery cable supports Remark Loosen the screws diagonally e Loosen each one of the screws 1 4 turn and remove them when they are completely loose 2 REMOVE Screw of the change selector ring Use an Alien spanner of 4 mm 3 REMOVE Chassis LD Remark e Place the motor with the chassis LS downwards and then put a screwdriver in the division slots a of the chassis Engine disassembly Engine Use the screwdriver only in the indicated points e The chassis LS should remain downwards e Separate the chassis after checking if the change selector ring and the clamp ring shaft have been removed Do not damage the contact surfaces of the chassis 3 REMOVE Tangs guide 3 9 ROCKER ARM TRANSMISSION AND CHANGE SELECTOR I REMOVE Guide bar of the change fork 1 short Guide bar of the change fork 2 long Change selector 3 Change fork 1 4 Change fork 2 5 Change fork 3 6 2 REMOVE Drive shaft unit 1 e Operation rod n 2 Driven shaft unit 2
43. btain the best results in fixing the valves flap smoothly in the valve seating while you turn it forwards and backwards by hand e Apply an abrasive thin paste on the front of the valve and repeat the steps afore mentioned LL Z Q N I Check and repairs Remark Make sure that the front and the seating are completely free from the abrasive paste after each fixing of valves Apply blue ink of mechanics Dykem on the front of the valve b Install the valve in the cylinder head Press the valve through the valve guide and against its seating to get good contact Measure the width of the valve fixing again If it is unspecified correct and polish the valve seating with emery 3 14 VALVES AND VALVE SPRINGS I MEASURE Free length a of the spring Unspecified gt Replace JL Free length of the valve spring 39 62 mm lt Limit 38 0 mm gt 2 MEASURE Inclination of the spring a Unspecitied gt Replace Vi Inclination limit of the spring n 7mm Engine Check and repairs 3 MEASURE Contact front of the spring Wear damages scratches gt Replace 4 MEASURE Internal Diameter of the valve guide Unspecified gt Replace Internal diameter of the valve guide Vi Inlet 5 000 5 012 mm lt Limit 5 042 mm Exhaust 5 000 5 012 mm Limit 5 042 mm 5 MEASURE Rod guide set Internal diameter
44. cement Insulator 2 Standard colour gt Replacement The standard colour is light brown 4 CLEAN e Spark plug Clean the spark plug with a spark plug cleansing or a wire brush 5 MEASURE Play between the electrodes a with a calibre of thickness Unspecified gt Adjustment to play JA Play between the electrodes n 0 7 mm 6 INSTALL e Spark plug Vi Spark plug 1 25 Kgf m 12 5 N m Checks and adjustments Engine Remark e Before installing the spark plug clean the surface of its seating and its gasket n case you do not have a torque gauge a good evaluation for the correct torque is to tighten 1 the spark plug by hand and then tighten from 1 4 to 1 2 turn to 2 Use always a new gasket 2 4 IGNITION POINT CONTROL Remark Before controlling the ignition point check all the electric connections linked into the ignition system Make sure that the connections are tightly and without rusty and also the earth connections must be very tight 1 REMOVE Top of the point control 2 INSTALL Stroboscope lamp 1 Inductive Tachometer 2 in the spark plug cable LL Z Q I Checks and adjustments 3 CHECK Ignition Point Steps for checking Get the engine started and let it warming up for some minutes Leave it working in the specified rotation Idling speed 1 300 1 400 rpm Check visually if the stationary
45. d press the screw 6 with the specified torque e Loose the screwdriver If all is correct with the gasket press the screw of the cover 1 with the specified torque Screws strut of the timing chain 1 0 Kgf m 10 N m Screw of the cover strut of the timing chain 0 75 Kgf m 7 5 N m 8 CHECK Play of valves Unspecified gt Adjust See section ADJUSTMENT OF THE VALVES SET in the CHAPTER 3 9 LUBRICATE e With motor oil x gt Engine assembly and adjustments 10 INSTALL Valves cover with the special gasket Lateral cover of the cylinder head with the special gasket e Screws with washers Valve cover 1 75 Kgf m 17 5 N m Screws lateral cover of the cylinder head 1 0 Kgf m 10 N m Il INSTALL Cap of checking point with the special gasket Central cap with O ring 12 INSTALL Gaskets inlet collector Inlet collector Screws inlet collector 1 0 Kgf m 10 N m 22 es op A 4 LO SN ON Carburettor 3 56 CARBURET TOR I Cable of the accelerator 16 Low spout 2 Lock valve unit 17 Cable of the choke 3 Spring of the lock valve 18 Choke unit 4 Drainage screw 19 Screw of the idling speed 5 Carburettor tank 6 Gasket of the tank 7 Body of the carburettor 8 Tang of the float 9 Float 10 Needle valve unit I1 High spout 12 Diffuser 13 Special gasket 14 Diffuser 2 15 P
46. ear of the 3rd 8 Driven gear of the 4th 9 Driven gear of the Ist 10 Ball bearing Il Ball bearing 12 Drive gear of the 5th 13 Drive gear of the 2nd 14 Drive gear of the 3rd 15 Drive gear of the 4th 16 Drive shaft Engine assembly and adjustments 5 INSTALL Bottom left fork of change L 1 Top left fork of change 2 Right central fork of change C 3 Guide bar short 4 Guide bar 2 long 5 Remark Install the change forks with the stamping mark in the sequence L beginning with the right 6 CHECK Operation of the change selector Irregular operation gt Adjust Remark Check if the operation of the transmission and the forks is normal turning the chan ge selector by hand Engine assembly and adjustments Engine 2 40 CHASSIS RUBBER SOLUTION YAMAHA N 1215 YAMAHA N 1215 Chassis RS Tang guide Hose of the sump vent Chassis LS Securing part Engine assembly and adjustments 3 41 CHASSIS RIGHT SIDE 1 APPLY Rubber solution on the surfaces in contact with the chassis Remark Not ALLOW that the rubber solution come into contact with the oil leaks a and B as it is illustrated in the following figure 2 INSTALL Tang guide 1 3 INSTALL Chassis LS in the chassis RS Remark Pound lightly in the chassis with a rubber hammer 4 PRESS Screws chassis
47. ear ratio Chassis CASTROL SAE 20W 50 API SH or high grade Wet type foam rubber cartridge CR7HSA NGK or U22FSR U THICK 0 6 0 7 mm Start ratio Z 14 Z 37 2 64 9 42 Z 18 Z 32 I 1 78 l 6 35 Z 19 Z 25 1 32 l 4 71 Z 22 Z 23 1 1 05 1 3 74 Z 24 Z 2I 1 0 88 l 3 14 Rieju chassis Suspension Front Rear Brakes Front Rear Tyres Front Rear Electric equipment Ignition system Generator Battery Fuse Bulb voltage and wattage Headlight Taillight Dashboard Indicators Odometer lighting Telescopic fork Bar 37 mm 340 cc CASTROL SAE I5Wbper bar Gas damper Disc 260 mm Disc 200 mm Bridgestone 90 100 19 55P with tube Bridgestone 120 90 16 63P with tube C D I Magneto generator AC 120 w 12 V 5 5 Ah 10 Amp I2V 55 60W H4 I2V 21 10OW I2V 1 2W 12V 10W Led Chassis Rieju chassis Chassis UNPACKING Unpack the motorcycle following the indications appearing on the same packaging after that it should be thrown according to current regulations AESTHETIC CONTROL Control visually that all the components of plastic material are correctly assembled and that the motorcycle does not show any scratch mark etc IDENTIFICATION DATA Engine identification number The data for identifying the engine A F 1
48. ed and 6 Front brake control full beam headlights KEYS The motorcycle is provided with two numeric code keys which allow To establish start ignition To turn on the lights To lock the steering STEERING LOCK Activate With the handlebar turned to the left get the key thorough into the lock and then turn it to the left Deactivate Turn the key to the right Rieju chassis Chassis SIDE STAND e Make sure the lateral rest is well fixed and it moves correctly likewise it is advisable to check frequently the hold up system made up of drive springs DASHBOARD l neutral gear warning light This warning light lits when the transmission is in the neutral gear position 2 Oil level warning light This warning light lits when the oil level is low 3 Coolant temperature warning light This warning light lits when the temperature of the coolant is too much high If this hap pens stop the engine immediately 4 Steering warning light This warning light twinkles when the steering switch moves towards the left or the right 5 Warning light of the full beam headlights This indicator lits when the full beam headlights are in use Rieiu chassi ieju chassis Chassis TYRES Dimensions Front 90 100 19 55 with tube Rear 120 90 16 63P with tube PRESSURE CONTROL The pressure of the tyres must be controlled and regulated with the tyres at room tem peratu
49. en the terminals 30 and 87 The tester should read 0Q When disconnecting the battery it should read infinite The tester should read infinite Checking the indicator relay Lamps 12V 10W Battery 12v Connect the indicator relay according to the sketch to verify if it sparkles the lamps can be replaced by one of I2V and 21W Instrument control Chassis 1 8 INSTRUMENT CONTROL DASHBOARD DIAGRAM To control the dashboard functions all the functions of the wires arriving to the dash board must be checked In accordance with the following chart Transmission Functions switch we i HE om gt gt Y Transmission ELECTRONIC C Km Sensor earth TRANSMISSION BL SIGNAL Sensor system y Chassis 1 9 SENSOR SYSTEM Neuter sensor To check this sensor the continuation between the terminal and the ground should be controlled With the neuter the On position it should read 00 When start the tester reads infinite Carburettor heater I V 7 000000 NE 6 Room temperature sensor 7 Carburettor thermal resistance Checking of the room temperature sensor Check the resistance with the tester between the ends of the sensor below 11 C 3 the resistance value is 00 When the temperature is increased you should disconnect at 16 C and the value is infinite Checking of the thermal
50. entation Introduction Torque Sub section Section Remark Illustrations frequently shown fixing or regulator screws specified with the letter Tr The number besides this letter indicates the quantity of identical Tr existing in the group or object component of the description and its corresponding illustration The letter without number indicates quantity I case of different screws shown in the same figure a number and a small letter will follow the letter Tr example Tr4a The re assembly of groups and components is usually carried out in opposite way to the disassembly interventions excepting specified description 1 4 OPERATIVE SIMBOLOGY L Loctite Lubrication oil pg i 6 Greasing grease Introduction Engine 1 5 WORK GENERAL RULES The following advice recommendations and warnings guarantee rational interventions in the maximum operative safety ruling out considerably the probabilities of accidents all kind of damage and time out Therefore we advise you to observe them scrupulously ADVICE Always use high quality equipments For raising the motor vehicle use manufactured equipment on purpose and subject the European regulations During the operations tools must be within arm s reach as far as possible according to a predetermined sequence and anyway never on the vehicle or in a hiding or inaccessible
51. er is in a condition to lay down for certain The present series of WORKSHOP GUIDES for two stroke engine provide the main information for the technicians of the sector Authorized Dealer etc to operate harmoniously on the modern concepts of good technique and safety at work The aim of these guides is about the standard technical interventions in the whole range of engi ne two stroke engine for RIEJU motor vehicles in the production phase at the spreading time of these manuals This information refers to the ENGINES of the motor vehicles Some information has been deliberately omitted since according to us it is an essential part of the basic technical knowledge Another possible information can be deduced from the SPARE PARTS CATALOGUES of each particular model Before reading the motor vehicle manual you are interested in it is important that you examine the first general pages where you will find the basic information for good item enquiry and the general nature technical concepts REMARK The manual provides you with the essential information for the standard inter vention procedures This information is supplied by the engine manufacturers 0 therefore this frees us to be responsible for any eventual error omissions etc The RIEJU company reserves the right to contribute modifications at any time without any previous notice For any request or further information please call to Rieju Technical As
52. f the handle bar Loosen the 2 lateral screws B F 55 to facili tate its removal Extract the top nut C F 55 and remove the top plate To extract the axle unscrew the nut D F 55 34 FRONT FOOTREST Unscrew the bolt A F 56 that hold on to the lower nut ATTENTION Take into account the posi tion of the spring for the later assembly 35 REAR FOOTREST Unscrew the bolt A F 57 that holds on to the lower nut Rieju chassis MEE i Chassis 36 REAR BRAKE LEVER Unscrew the bolt A F 58 and remove it 37 DRIVE CHAIN GUARD Unscrew the 2 bolts A F 59 and remove the guard 38 TRANSMISSION CHAIN Remove the 2 fixing screws A F 60 from the guard and take it out Extract the securing clip B F 61 of the link and remove it Chain tensioning see page 25 ANI ATTENTION Place the clip in the direction of the chain turn Rieju chassis et bn Chassis 39 REAR BRAKE PUMP Unscrew the 2 bolts A F 62 that hold The brake pump on to the chassis To remove the pump it is necessary to dis connect the cable of the STOP switch B F 62 and unscrew it Remove the clamp C F 62 of the brake li quid feeding tube and empty it in tray ATTENTION Brake liquid is abrasive 40 KICK STARTER Unscrew the nut A F 63 and pull the lever to remove it ATTENTION The assembly in different position from the original can reduce the
53. g by the peephole placed in the pump Change For the front brake remove the cover A F 17 after taking the screws out B F 17 For the back brake remove the cap C F 18 The quality of the used liquid should comply with the specified regulations since otherwise the rubber gaskets can wear causing leaks and reducing the effectiveness of the brake Recommended brake liquid DOT 4 ATTENTION Brake liquid is abrasive Chassis ADJUSTMENT OF THE MINIMAL INTERVAL OF TURN Start the engine and warm it up for some mi nutes in the 1000 to 2000 rpm interval spee ding up till the 4000 to 5000 rpm When the engine responds quickly to the acceleration that means it is hot Adjust the minimal zone of the engine turning the screw for gas adjustment A F 19 Screw to the right to speed up and to the left to slow down Control the ideal interval of the engine with an electronic tachometer connected to the spark plug cable Rieju chassis Chassis TENSION ADJUSTMENT OF THE TRANSMISSION CHAIN The adjustment of the chain carries out loosening the rear axle of the wheel and screw in or unscrew the adjacent bolts and nuts A F 20 always getting the same distance on both sides of the axle ATTENTION wrong alignment of the chain and the wheel can make the chain comes out as well as give stability problems in the motorcycle To control and adjust the chain you should operate on the rea
54. he points after installing the securing screws If it is necessary loosen one of the screws lightly in order to tighten the extractor position Cover the point of the crankshaft with the spanner to avoid damages 3 REMOVE Start gear e Washer 4 REMOVE Plate 2 e Start gear 1 Engine disassembly 5 REMOVE Guides of the timing chain 1 Timing chain 2 3 3 CLUTCH Remark The clutch unit can be removed with the assembled motor in the frame To be able to do it take the following parts out e Exhaust e Foot rest e Brakes pedal Start Pedal I REMOVE Chassis cowlings RS Remark Loosen screws diagonally gt Or Engine disassembly Engine 2 REMOVE Gasket 1 Tangs guide 2 3 EXTRAER Screws of the pressure plate 1 Clutch springs 2 Pressure plate 3 Friction plates 4 Separators 5 Remark Loosen the screws of the pressure plate diagonally 4 REMOVE e Operation rod 6 Ball 7 Engine disassembly Engine 5 LOOSE e Nut clutch drum 1 Remark e Smooth the rim of the clamp rings 2 e Loosen the nut 1 from the clutch drum while the drum is hold with the universal clutch support 3 6 REMOVE Nut of the clutch drum I Clamp rings 2 Clutch drum 3 Pressure Washer 4 Clutch hood 5 Space washer 6 Washer 7
55. ickness of the friction plates Unspecified gt Replace the friction plates unit Measure in 4 different positions Thickness friction plates n 3 0 mm Limit 2 8 mm Check and repairs A W 3 CHECK e Separators Damages gt Replace the separators unit 4 MEASURE e Separators strain Unspecified gt Replace the separators unit Take the measurements on a plane table with the help of a thickness calibre 1 Strain limit separators Lower than 0 05 mm 5 CHECK e Clutch springs Damages gt Replace the springs units 6 MEASURE e Free length springs a Unspecified gt Replace the springs unit Free length springs 33 0 mm lt Limit 31 0 mm gt fns annn i Check and repairs 7 CHECK Nails of the hood 1 Rims wear damages gt Eliminate the rims or replace the hood Grooves in the clutch drum 2 Rims wear damages gt Replace the clutch drum Remarks e Rims in the nails of the hood and in the grooves of the clutch drum results in an irregular operation UDI ov 3 26 ROD OPERATION CHECKING 1 CHECK e Ball bearing l Rod operation 2 Wear cracks damages gt Replace Engine LL Z Q N I Check and repairs 3 27 FORKS AND CHANGE SELECTOR CHECKING 1 CHECK Fork extension 1 Extremities of the change forks 2 Scratches w
56. ilot screw unit of air Carburettor Engine 3 57 DISASSEMBLY Remark All the parts here below can be cleaned and inspected without disassembling the carburettor All the internal parts excepting the choke Lock valve Needle of the lock valve All the spouts Float Needle valve Seating of the needle valve Diffuser Needle of the lock valve I EXTRACT Carburettor tank 1 Gasket of the tank 2 EXTRACT Tang of the float 1 Float 2 3 EXTRACT Needle valve 1 Seating of the needle valve 2 Carburettor Engine 4 EXTRACT High spout 1 Diffuser 2 e Special gasket e 5 EXTRACT Vi Pilot screw unit of air 1 Low spout 2 49 is N N CS C C G L4 C Dee 7 3 58 CHECKING 1 CHECK Body of the carburettor Carburettor tank Place of the spouts Cracks damages gt Replace Fuel leaks Obstruction Clean as mentioned before Body of the carburettor tank Contamination gt Clean Carburettor Engine Steps for the cleaning Wash the whole carburettor with kerosene or petrol Do not use solutions with a chemical products base for cleaning the carburettor Blow all the leaks and spouts with compressed air 2 INSPECT e Float Damages gt Replace 3 INSPECT Needle valve 1 Seating of the needle
57. ing parts e Seat e Side cowling e Fuel tank e Exhaust pipe e Carburettor e Clutch cable e Spark plug Cable e Securing base of the engine 1 REMOVE e Spark plug Inlet manifold 1 2 REMOVE Top of the point control with the gasket 1 Central cap with the gasket 3 REMOVE Valves lining with the gasket e Side covers of the cylinder head with the gasket Engine disassembly I Engine 4 ALIGN Magneto mark a with the stationery point b of the chassis cowling Remark Rotate the crankshaft anticlockwise with spanner Steps for alignment with TDC Rotate the crankshaft anticlockwise aligning the mark a with the top dead centre b Align the mark I of the control gear with the stationary point d of the cylinder head So the piston will remain in top dead centre TDC Remark e Check if the piston is in the TDC of the compression time e f it is not rotate the crankshaft anticlockwise completely once again 5 REMOVE Screw adjuster of the timing chain 1 Adjuster unit of the timing chain 2 6 REMOVE Screw control gear 1 Particular washer control gear 2 LL Z Q N I Engine disassembly 7 REMOVE e Screws cylinder head Cylinder head Remark e Loosen each one of the screws 1 4 turn and remove them when they are completely loose Loosen the screws beginning
58. justment Place the motorcycle in a flat surface Place a jack or a support under the engine to guarantee the carburettor in the vertical position Connect the gauge of fuel level 1 in the drainage pipe 2 Loosen the drainage screw 3 Hold the gauge vertically near the line of the carburettor tank Measure the level of fuel a with the gauge f the level is incorrect adjust it Extract the carburettor Inspect the valve seating and the needle valve f those pieces are worn replace both f they are normal adjust the float level by bending the needle support on the float slightly Install the carburettor Control the level of fuel again d 541 JULI Start the rocket 4 M RIEJU S A c Borrassa 41 E 17600 FIGUERES GIRONA SPAIN Telf 34 972500850 Fax 34 972506950 WWW c 000 0 c0m e mail Griejumoto com
59. ly to the integrated tool A F 4 in the run ning board Introduction Engine 1 7 SPARK PLUGS I Insulator 2 Body 3 Lining 4 Electrode 5 Earth electrode 6 Thread SPARK PLUGS CONTROL AT 1 000 Km Do not to touch the spark plug if the motor is hot The coal tip and the insulator coloration around the central electrode provide with useful information about the thermic degree of the spark plug the carburation the lubrication and the overall condition of the engine A light brown insulator coloration indicates the correct general operation Black sooty tips dry to the touch opaque indicate that the operation temperature is too low spark plug thermic degree is too high too rich carburation or faulty ignition Off white insulator indicates a mixture too weak or spark plug thermic degree too low spark plug too hot Verify the distance between the electrodes F 6 although the spark plug is new using a calibrated calibre of thickness and eventually register it working only on the earth electrode Introduction Engine 1 8 SPARK PLUG MAINTENANCE The spark plug maintenance consists in removing it periodically from the motor to check visually the conditions and the distance between the electrodes Proceed to clean the electrodes and the insulator carefully using a wire brush Eliminate possible waste with a strong jet of compressed air L
60. mit 0 03 0 07 0 12 mm Secondary ring scraper lt Limit gt 0 02 0 06 0 1 2 mm gt 2 PLACE Piston rings in the cylinder Remark e Push the ring with the piston top in order that it is in parallel with the cylinder base a 5 mm 3 MEASURE Play among tips Unspecified gt Replace Remark e You cannot measure the play among tips in the extension ring of the oil ring f the oil ring has excessive play replace the three rings Play among tips Top ring Limit 0 15 0 30 mm lt 0 40 mm gt Secondary ring scraper Limit 0 30 0 45 mm lt 0 55 mm gt Oil ring 0 2 0 7 mm Y Check and repairs Engine 3 21 BOLT CHECKING 1 CHECK Bolt Blue coloration grooves gt Replace and immediately control the lubrication system 2 MEASURE Play piston bolt Steps for measuring Measure the external diameter of the bolt a Unspecified gt Replace the bolt External diameter bolt 14 991 15 000 mm lt Limit 14 975 mm gt Measure the diameter of the bolt place in the piston b Calculate the piston bolt play using the following formula Piston bolt play Internal diameter bolt place b External diameter bolt a e f it is unspecified replace the piston Play piston bolt 0 009 0 013 mm Check and repairs 3 22 CRANKSHAFT I MEASURE Non alignment crankshaft Unspecified gt Repl
61. n disconnecting the battery it should read infinite The tester should read infinite Electric start system Chassis Connect the engine to a charged battery and check it turns vigorously Connect the engine to a charged battery and check it turns vigorously In case that it doesn t rotate correctly you should disassemble the engine and make the following verifications Correct operation limit of dynamo brushes 3 5mm Wear limit of the brush collector 2Imm Depth of the collector insulation l 5mm Resistance of the rotor coils 0 0170 0 0210 20 IMPORTANT Check the insulation between the sheets of the collector and the ground If the engine has the suitable values the following operations must carried out Polish the surface of the collector and revise the depth of the insulation e Reduce the insulation between the sheets of the collector with a saw till reaching 1 5mm Check the pressure of the springs of the brushes Check that the plate of brushes is not connected to earth See the bearings set and that the armature doesn t graze the stator Do not grease excessively since in rotation the brush collector would dirty Lighting system Chassis 1 7 LIGHTING SYSTEM Adjustment of the beam light height of the headlight Horizontal Intensive light Height to the centre With the driver seated on the vehicle the headlight should be adjusted so
62. of the cylinder in a cross shape and right angled to the the crankshaft Then calculate the average of the measurements Check and repairs LL Z Q I c Diameter of the cylinder 54 000 54 018mm T conical limit 0 05mm Ovalidad 0 0 Imm maximum D T maximum D or D maximumD or D maximum D or D or D maximum D or D or D e elf it is unspecified rectify or replace the cylinder and replace the piston and the rings altogether 2nd Step Measure the brim of the P piston with a micrometer a 4 5 mm from brim of the piston Standard 53 977 53 996mm Over measure l It is unspecified replace the piston and the rings altogether 3rd Step Calculate the cylinder piston play using the following formula Cylinder piston set Diameter of the C cylinder Diameter of the P piston brim Set cylinder piston 0 020 0 028 mm J lt Limit gt 0 15 mm e If it is unspecified rectify or replace the cylinder the piston and its rings altogether Check and repairs A jj 3 20 RINGS CHECKING I MEASURE Lateral play Unspecified gt Replace the piston and its rings altogether Remark e Eliminate the carbon sediments from the grooves of the piston rings before mea suring the lateral play Lateral play rings of the piston Top ring Li
63. of the guide Diameter of the rod valve Inlet 0 010 0 037 mm lt Limit 0 08 mm gt Exhaust 0 025 0 052 mm lt Limit 0 10 mm gt Vi Limit of rod guide set Unspecified gt Replace the valve guide LL Z Q N I Check and repairs 6 MEASURE Warping valve rod Unspecified gt Replace Warping limit 0 01 mm 3 15 CAMSHAFT CHECKING 1 CHECK Cam salient Groove scratches blue coloration gt Replace 2 MEASURE Cam measurements a and b Unspecified gt Replace Cam measurements Inlet a 25 881 25 981 mm lt Limit 25 851 mm b 21 195 21 295 mm lt Limit 21 165 mm gt Exhaust a 25 841 25 941 mm lt Limit 25 811 mm gt b 21 05 21 15 mm lt Limit 21 02 mm gt Check and repairs 3 CHECK Oil leak in the camshaft Obstruction gt Compressed air blowing 3 16 ROCKERS AND THEIR SHAFTS CHECKING 1 CHECK Cam contact surface 1 Adjuster surface 2 Wear grooves scratches blue coloration gt Replace Steps for checking Check if the two contact areas of the rockers have signs of abnormal wear Orifice of the rocker shaft Cam contact surface Excessive wear gt Replace Check the surface conditions of the rockers shaft Grooves scratches blue coloration gt Replace or check the lubrication system Measure the internal diameter of the
64. ponent described and illustrated Letters not followed by a number indicate single screw In case of different screws being referred to in the illustration the letter Tr is followed by number and small letter for instance Tr4a Unless otherwise specified units and components are reassembled by pro ceeding in the reverse order of removal Introduction Chassis GENERAL WORK RULES The advice recommendations and warnings given hereafter are aimed at ensuring maximum work safety as well as at considerably reducing the risk of accidents personal injury equipment damage and idle times They should therefore be strictly adhered to ADVICE Only use quality tools and equipment Only use equipment conforming to EU Directives for lifting the vehicle During operations always keep tools and equipment at hand possibly laying them out according to the sequence in which they are to be used Absolutely avoid putting them on the vehicle itself out of sight or in poorly accessible places Always keep the work area clean and tidy e When tightening screws or nuts start with the larger diameter or inner fasteners and tighten them in progressive pulls in accordance to a criss cross pattern Preferably use open end box wrenches by pulling and not pushing Adjustable wrenches 1 should only be used in case of emergency i e when a properly sized wrench is not available They should preferably not
65. r unscrew the 3 bolts B F 31 that hold the tank on to the chassis Following remove the cap and separate the cover from the Tank C F 32 18 CARBURETTOR Remove the seat and the fuel tank Loosen the 2 clamps A F 33 that hold the carburettor on to the filter box and to the en gine Unscrew the top cover of the carburettor B F 33 and disconnect the cable of the gas After disconnect the air intake sleeve and the rest of tubes ATTENTION Pay attention to the position of the tubes for the later assembly Rieju chassis 19 SIDE STAND ATTENTION Hold the motorcycle before carrying out this operation Remove the tensioning spring A F 34 After unscrew the bolt B F 34 20 FRONT MUDGUARDS Unscrew the 4 bolts A F 35 two in each side which hold the mudguards on to the fork Remove it by the front part Chassis Rieiu chassi chassis Chassis 21 ENGINE Remove the front lateral plates the carburettor and the exhaust To make the task easier remove the rear brake lever Disconnect the spark plug A F 36 the clutch cable B F 36 and the ventilation tube of the engine C F 36 To gain access to the top part disconnect the 2 terminals of the engine D F 37 Unscrew the 2 bolts E F 36 of the engine front support After unscrew the 4 bolts F F 36 that hold the engine ANI ATTENTION Extract the engine from the chassis
66. r axle of the wheel always working in the maximum tension point of the chain To control the play turn the rear wheel on several times and check the tension in diffe rent places to meet the tensest point The motorcycle should be placed vertically with the two wheels on the floor and the loo seness of the chain ought to be from 20 to 35 mm F 21 Try not to tighten the chain excessively since it could damage the engine and the transmis sion keep the chain tension within the specified limits in the following sketches It is necessary periodically cleaning and greasing of the chain The chain is composed of lots of pieces that work together correct maintenance of the chain is required to avoid quickly wear so therefore it is convenient to grease the chain periodically with special oil for this purpose Before lubricating it is necessary to clean the chain in order to get the dirt off Clean with brush or cloth and then apply the lubricant between the lateral plates and in all the central rollers Disassembly Rieju chassis Chassis Il SEAT Unscrew the nut A F 1 located inside the cavity of the rear wheel After lift the seat off the back and pull it backwards to remove it from the front catch B F 2 2 LATERAL COVER Remove the seat Unscrew the bolt from the back A F 3 Following pull the part to remove it 3 FRONT LATERAL COVER Unscrew the two bolts
67. re REAR Position FRONT 1 7 kg cm2 REAR 2 0 kg cm2 FUEL TANK Unscrew the cap and refuel the tank paying attention not to pass the limit if after filling some petrol residues are showed on the motorcycle wipe them off immediately Use normal unleaded petrol Fuel tank capacity Total 5 5 litres Rieju chassis Chassis TRANSMISSION OIL Change Place the motorcycle in a flat surface 2 Warm the engine up for some minutes 3 Pull the engine up Place a tray for the oil under the engine 4 Unscrew the emptying nut A F 15 and the loading cap B F 16 to allow the oil to flow 5 When it is completely emptied screw tightly the emptying nut A F 15 6 Fill the engine with oil The loading cap has a control of maximum and minimum loading of oil Place the loading cap B F 16 and tighten it It is advisable to use CASTROL oil SAE 20W 50 API SH or high grade 7 Get the engine started and warm it up for some minutes During the warming check any possible leak of oil If so pull the engine up immediately and find out the cause Rieju chassis BRAKE OIL Control When the oil level is going to be checked turn the handlebar to verify that the upper part of the main cylinder is levelled out Check the oil level is above the mark of the minimum level in the tray of the rear brake And control there is enough oil for the front brake observin
68. rns with the other one Use the tool until realizing that the crankshaft adjusts in the ball bearing To avoid scratches in the crankshaft and to facilitate the installation apply grease in the rims of the constrained ring and motor oil in the ball bearing 3 INSTALL Rocker arm shaft Always use rubber new rings Remark When installing the shaft of the rocker arm align the puncture mark a of the crankshaft gear with the puncture mark b of the rocker arm gear 4 INSTALL Neuter Switch Engine assembly and adjustments 3 37 CHANGE SELECTOR 1 2 Kgf m 12 N m d Engine I Guide bar long 2 Change fork n 3 3 Change fork n 4 Change selector 5 Segment 6 Guide bar short 7 Change fork n 2 Engine assembly and adjustments Engine 3 38 TRANSMISSION FORKS AND CHANGE SELECTOR INSTALLATION I MEASURE Length of the drive shaft a Length of the shaft drive 82 25 83 45 mm 2 INSTALL e Operating rod n 2 1 In the orifice of the drive shaft 3 INSTALL Shaft of the operation rod 1 New gasket 2 4 INSTALL Special gasket 2 In the groove of the drive shaft Engine assembly and adjustments 3 39 TRANSMISSION 0 7 Kgf m 7 N m I Pinion 17 Clamp plate 2 Constrained ring 18 Ball bearing 3 Ball bearing 4 Driven gear of the 5th 5 Drive shaft 6 Driven gear of the 2nd 7 Driven g
69. rockers orifice Unspecified gt Replace LL Z Q N I Check and repairs Internal diameter rocker 10 000 10 015 mm lt Limit 10 03 mm gt e Measure the external diameter b of the rockers Unspecified gt Replace External diameter rocker shaft 9981 9991 mm lt Limit 9 95 mm gt 3 17 CAMSHAFT CHECKING 1 CHECK Timing Chain Rigidity damages gt Replace the chain and the gear 2 CHECK Control gear Damages wear gt Replace the gear and the timing chain 4 tooth 1 Correct 2 Roller 3 Gear 4 3 CHECK Timing chain guides exhaust 1 Timing chain guides intake 2 Damages wear gt Replace Check and repairs 3 18 TIMING CHAIN STRUT I CHECK Ratchet brace operation Irregular operation gt Replace Steps for checking While the adjuster rod is lightly pressed by hand use a screwdriver to turn totally the adjuster rod clockwise When get the screwdriver out press lightly by hand and make sure that the adjuster rod moves forwards smoothly On the contrary replace the adjuster chain unit 3 19 CYLINDER AND PISTON 1 CHECK Cylinder and piston walls Vertical scratches gt Rectify or replace the cylinder and the piston 2 MEASURE Cylinder piston play Steps for measuring Ist Step Measure the C diameter of the cylinder Remark e Measure the C diameter
70. ses of the sensor of the wheel Going on pressing the button TRIP the option MILES mph and kilometres hour km h will be displayed and with the button TRIP we will choose km h Keeping it pressed for 3 seconds the word PULSE will appear on the screen and above it in the right part of the screen RPM will be displayed then we will insert the value corresponding to the RPM picking the fixed value pressing the button TRIP Keeping the button TRIP pressed for 3 seconds more we will turn back to the INITIAL screen The return to the initial screen becomes effective Automatically after 6 seconds without operating the button TRIP TO CHECK IF THE INPUT DATA IS THE RIGHT ONE WE SHOULD TURN ON THE IGNITION START THE ENGINE AND IN TWO SECONDS THE ENTERED DATA WILL BE DISPLAYED ON THE SCREEN DURING TWO SECONDS VERIFYING THAT IT IS CORRECT IMMEDIATELY AFTER THE INITIAL SCREEN WILL APPEAR The dashboard is ready to be used giving the right information MAE DASHBOARD SET OF VALUES VALUES TO BE INSERTED IN THE DISPLAY CONFIGURATION Pulses of RPM 6 Electric Diagram ELECTRIC DIAGRAM SENSOR C Km AZ Sefial RJ 5V NE 1215141511678 ELEC E 22225 3d VYNAVYHIJ 0 000 160 8000 NOMENCLATURA DE COMPONENTES CODIGO DE COLORES AMARILLO RJ
71. sistance Service 1 2 UPDATING GUIDE The updating will be send in a reasonable period Each new CD ROM will replace the one you have already got The index will be updated in case modifications and changes of the pages inside no longer guaran tee a rational enquiry of the manual IMPORTANT The series of Workshop Guides has to be considered as a work tool strictly speaking and it can remain in value through time only if it is constantly updating Introduction Engine 1 3 WRITING SIMBOLOGY ATTENTION Some caution advice and information as regards to the safety of the motorcyclist vehicle user and the safeguard of the whole vehicle ATTENTION Descriptions relating to some dangerous interventions for the maintenance engineer the repair technician the workshop staff or strangers for the atmosphere for the vehicle and for the equipments FIRE RISK Operations which could cause fire DANGER OF EXPLOSION Operations which could cause explosion TOXIC AG Evident danger of poisoning or inflammation of the first respiratory track MECHANICAL MAINTENANCE Operations to be performed only by an expert mechanic ELECTRICAL MAINTENANCE Operations be performed only by an expert electrical electronic technician NO Operations which must be avoided ENGINE WOKSHOP GUIDE Information derived from this documentation SPARE PARTS CATALOGUES Information derived from this docum
72. stroke when starting Rieju chassis 41 SWING ARM Chassis Remove the chain the rear brake pin the rear wheel and the shock absorber Unscrew the nut A F 64 and remove the axle B F 65 42 TORQUE TORQUE TABLE Element N m Notes Front wheel bolt 38 52 3 8 5 2 Front wheel bolt block I7 23 7 23 HEE Rear front bolt 72 98 7 2 9 8 FB 8 Front Rear brake pin 24 36 2 4 3 6 Muffler 6 10 0 6 1 0 Lateral coupling of the exhaust muffler 6 10 0 6 1 0 Engine fixing screws 32 36 3 2 3 6 Handlebar control screw 2 4 0 2 0 4 Shock absorber screws 38 52 3 8 5 2 Fork bolt 5 69 51 69 MNB NP Handlebar fixing bolt 18 24 1 8 2 4 Steering top nut 18 24 1 8 2 4 Steering middle nut 25 34 2 5 3 4 Hs 8 Swing arm bolt 60 75 9 0 7 5 FI P Grease Electric system 8 Chassis 1 ELECTRIC SYSTEM 1 1 CAUTIONS 3 1 2 GENERAL WIRING HARNES 3 1 3 BATTERY 4 1 4 RECHARGE SYSTEM AND LIGHTS 6 1 5 IGNITION SYSTEM 7 1 6 ELECTRIC START SYSTEM 10 1 7 LIGHTING SYSTEM 12 1 8 INSTRUMENT CONTROL 15 1 9 SENSOR SYSTEM 16 1 10 DASHBOARD PROGRAMMING T 1 11 ELECTRIC DIAGRAM 19 Electric system Chassis l CAUTIONS There are some important cautions before beginning to inspect or repair the electric system Pay particular attention to the polarity of the battery Always check the condition of the ba
73. t with the chassis properly I CHECK e Chassis Cracks damages gt Replace Oil leaks Obstruction gt Blow the leaks with compressed air 3 32 CLAMP RINGS AND WASHERS 1 CHECK Clamp rings Washers Damages loose deformed gt Replace Engine assembly and adjustments 3 33 MOTOR ASSEMBLY AND ADJUSTMENTS I VALVES ROCKERS AND CAMSHAFT 0 8 Kgf m 8 N m o I Clamp valves 2 Clamp seating 3 Spring 4 Constrained ring 5 Spring seating 6 Valve inlet 7 Valve exhaust 8 Locknut 9 Adjuster 10 Rocker II Rocker shaft intake 12 Rocker shaft exhaust 13 Clamp ring 14 Valve guide 15 Camshaft 16 Clamp plate CD Engine assembly and adjustments Engine To assemble the motor replace the following parts with other new ones e Particular ring e Gaskets e Constrained rings e Copper washers e Clamp washers e Clamp rings 3 34 VALVES AND VALVE SPRINGS CHECKING I ELIMINATE THE RIMS From the extremity of the valve rod Use an emery stone to eliminate the rims 2 APPLY Oil of disulphide molybdenum In the valve rod and in the constrained ring Oil of disulphide molybdenum 3 INSTALL Spring seating 1 New constrained ring 2 Valve 3 In the cylinder head Valve 4 Spring Clamp seating 5 Remark Install the valve springs with the biggest passage upwards a
74. the intensive beam of light is underneath the horizontal of the headlight In the event of changing a lamp do not handle the internal part of the headlight and take the new lamp with a clean cloth Checking of the switches Control of the ignition lock With the tester check the continuation between the wires of the ignition lock In the ON position continuation between wires Colour GR AND OR GR B AND YE Lighting system Chassis Control of the right hand drive lights switch and starter switch SWITCH eo Check the continuation among the wires of the connector In the ON position of the starter switch check the continuation among the wires Colour W BL AND W BL Control of the right hand drive Lights switch indicators switch and horn push button Check the continuation between the wires of the connector Horn push button In the ON position Continuation between the wires Colour R B Indicator switch In the RIGHT position Continuation between the wires Colour Dark GR and W BR In the LEFT position Continuation between the wires Colour W BR and BR Lights switch In the Hi position Continuation between the wires Colour YE and BL R In the HIM position Continuation between the wires Colour BL R and Light GR Lighting system Chassis Checking of the ignition relay With the relay terminals 85 and 86 connected to battery check the continuation betwe
75. ticlockwise Check that the copper wire sticks out the HT wire Resistance 5KQ 20 20 C If the values of the coil and the spark plug pipe are correct then check the magnetic flywheel SENSOR CHECKING PICK UP SAS 1NdINI 40 1109 Resistance of the coil sensor of impulses Connect the tester between the wires white green and white blue Resistance 2900 20 20 If all the devices give the correct values and the problem persists check that the black and violet wires of the CDI switch come up to 12 V when ignition is in the ON position In case all the values are fulfilled CDI should be replaced Important cautions Do not connect either disconnect wires or connections with the engine running Do not electric weld either spark off with CDI connected Before replacing CDI check that the connections and the wiring are in good conditions Electric start system Chassis 1 6 ELECTRIC START SYSTEM Start system diagram Starter 2 Start relay 3 Start switch 4 Fuse I0 A 5 Battery ELECTRIC START SYSTEM CHECKING Check with the tester the continuation of the 10 A fuse If the fuse is correct check the battery according to the section about it Minimum voltage of the battery 12 5 V Checking of the start relay With the terminals 85 and 86 of the connected relay to a battery check the continuation between the terminals 30 and 87 The tester should read 0 O Whe
76. till the mark a is aligned with the stationary point b Align the mark I c of the control gear with the stationary point d of the cylinder head Install the timing 1 chain in the control gear 2 and install the gear in the camshaft Engine assembly and adjustments Engine Remark When installing the control gear keep the timing chain as much tense as possible in the exhaust side can occur or the motor can be out of point Do not rotate the crankshaft during the installation of the camshaft Damages Extract the cable from the timing chain 4 INSTALL Clamp plate 5 INSTALL Screw gear 2 Screw gear of the timing chain 2 0 Kgf m 20 N m Remark Install the screw while fastening the nut of the flywheel magneto with a spanner 6 CONTROL Marks of the flywheel a Align the stationary point b with the cover of the chassis LI e Marks of the control gear I d Align the stationary point c with the cylinder head Non aligned gt Adjust LL Z Q N I Engine assembly and adjustments 7 INSTALL e Strut of the timing chain Steps for the installation Extract the screw from the cover of the strut While the bolt of the strut is pressed lightly with the hand use a screwdriver to turn the bolt of the strut clockwise completely With the bolt completely tight install the gasket 4 and the strut of the chain 5 an
77. ttery before beginning any repair Charge the battery out of the vehicle to avoid possible acid leaks or failures in contact with the battery charger which could damage some electronic component Do not use the battery either other connections with the engine running since you could damage some electronic components Do not use different lamps to the specified ones either in the lights nor in the dashboard Do not weld either operate with machines which can produce electric sparks if CDI is not disconnected otherwise it could be damaged Before taking measures of electric element make sure that the part is not hot All the electric connections should be clean and well tight 1 2 GENERAL WIRING HARNESS Checking in the wiring harness Check visually that the wiring is not worn and the connectors and terminals not much tight or dirty If so they should be replaced In the event of any fault is observed visually the continuation with the tester should be checked between wires of the same colour and section To be able to check this the installation should be disconnected The wires of the same colour and section should have continuation among them TESTER SCALE OX I Chassis 1 3 BATTERY CONTROL OF THE BATTERY CONDITIONS To be able to check the battery it is advisable to take it out of the vehicle When disassembling unplug the first negative terminal to avoid possible short circuits
78. ubricate the thread of the spark plug with motor oil or grease that conducts electricity then screw it by hand until the bottom Then press it moderately with the respective spanner see torque in F 6 It is necessary to replace all spark plug with fissures in the insulator or corroded electrodes 1 9 SPARK PLUG REPLACEMENT AT 5000 Km At the foreseen kilometres replace always the spark plug with a new one choosing one of those that the Company RIEJU S A recommends When the discharged spark plug is being eliminated inspect always its general look as previously stated to check the good state of the engine 1 10 MOTOR REMOVAL To remove the motor from the frame look up in the Workshop Guide in Cyclist section where you will find all the steps to follow MOTOR DISASSEMBLY The manufacturer is exempt from any responsibility caused by damages of any nature in a disassembly and a new assembly of the engine and each of its parts owing to the use of unsuitable tools for this kind of interventions WF Exclusively use ORIGINAL RIEJU SPARE PARTS General specifications Engine 2 1 TORQUE GENERAL SPECIFICATIONS The following table specifies the fixed torques with ISO standard thread The torque specifications for components or special units are indicated in the chapters of this guide referring to ISO To avoid strains screw the units gradually and cross them in one or alternative goes to obt
79. with the smaller number The stamped numbers on the cylinder head indicated the torque sequence 8 REMOVE Guide of the timing chain exhaust 1 Tangs guide 2 Gasket cylinder head 3 e Screws cylinder head Clutch cable hold Cylinder 9 REMOVE Tangs guide 1 Gasket cylinder 2 10 REMOVE Clamp rings of the bolt 1 Bolt 2 Piston 3 Engine disassembly Engine Remark e Before removing the clamp rings of the bolt cover the cylinder with a clean cloth to avoid that something falls inside the engine e Before removing the bolt take the slot flanges out of the clamp rings and the orifi ce rim Once the flanges are removed it there are still difficulties for getting the bolt out use the corresponding tool 3 2 MAGNETO FLYWHEEL Remark The magneto flywheel can be removed while the engine is assembled in the frame releasing the change pedal I EXTRAER Chassis cowling LS Drive of the neuter switch Nut magneto 1 Flat Washer 2 Remark Loosen the nut of the magneto while hold the magneto with the rotor support mag neto 3 Engine disassembly HSIIONSA 2 REMOVE Magneto flywheel 1 Cotter Remark Remove the flywheel magneto with the rotor extractor 2 Centre the rotor extractor of the magneto flywheel Make sure that the play bet ween the extractor and the flywheel is the same in all t
80. y have to be progressively reached in consecutive goes The loosen and tighten operations of the parts in aluminium alloy sump must be carried out when the motor cools down Always use screwdrivers of suitable size for the bolts in use Never work in awkward conditions neither in an unstable situation of the motor vehicle Never use a lining or an elastic ring again e Never unscrew or screw down bolts and nuts with clips since besides it does not exert enough blockade force the bolt cap or the nut hexagon can be damaged Do not hit with the hammer or another tool on the spanner to loosen or tighten bolts and nuts F 2 Do not use the extension bar for the spanner F 3 Introduction Engine Never use under no circumstances free flames Never leave open and not suitable containers with fuel blocking the pass near to heat sources etc Never use fuel like a cleansing detergent for the motor vehicle or for the workshop floor Ax The components must be cleaned with a low grade of inflammability detergent amp Never suck in or blow in the fuel pipe Never carry out welds in the presence of fuel Remove the tank although it is totally empty and disconnected the negative lead of the battery Never leave the motor running in closed premises or without air vent Before each intervention make sure of the motor vehicle is perfectly steady A The front wheel should be anchored preferab

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