1 - Motor-Land
Contents
1. Engine Rieju Engine 6 ENSURE that the clutch assembly is working order To do so ensure that the iron discs are in good condition that the notches on the cork discs are not too deformed and that their coating is not burnt Check that the grooves on the clutch boss are not too deeply marked perform the same check on the slots of the clutch housing Also check that the clutch springs are not shorter than the permissible threshold of 29 5 mm F 31 if they are shorter replace them 7 CAREFULLY clean the carbon crust from the piston top by means of a common scra per taking care not to damage the piston itself Check the piston skirt for streaks or seizing Check that it is firmly mated to the lubricated piston pin the surface of which must be in perfect condition Make sure that the piston pin can be fitted by manual pressure and that it does not yield under its own weight 8 CHECK the piston rings for faults of any type and make sure that the clearance between the two ends is within the values shown in the chart RINGS DISTANCE New 0 15 0 30 mm Used Up 1 2 mm The checks must be carried out using a feeler gauge The piston ring must be placed in the cylinder in a horizontal position F 32 9 CHECK that the cylinder water jacket does not have seizing notches or wear and that there is no scoring of any kind By means of a bore gauge check the cylinder bore in two directions at 90 the one fro2. 6 5 0 8 5 0 8 6 7 6 6 8 1 25 10 1 25 12 1 25 6 5 0 8 12 1 25 12 1 25 5 0 8 4 1 25 4 1 25 7 0 7 MIO x 1 25 TORQUE SETTING N m 20 25 14 16 24 26 16 20 45 50 2 5 3 5 4 6 4 6 4 6 4 6 6 8 3 4 9541 10 12 2 4 10 12 17 18 24 26 10 12 5 2 65 75 55 60 3 55 26 28 Kg m 2 25 1 4 1 6 2 4 2 6 1 6 2 0 4 5 5 0 0 25 0 35 0 4 0 6 0 4 0 6 0 4 0 6 0 4 0 6 0 6 0 8 0 3 0 4 0 9 1 1 1 0 1 2 0 2 0 4 1 0 1 2 1 7 1 8 0 1 0 2 2 4 2 6 1 0 1 2 0 1 0 2 6 5 7 5 5 5 6 6 0 3 0 5 2 6 2 8 turn until it stops 14 16 3 4 43 45 1 4 1 6 0 3 0 4 4 3 4 5 Engine naj EX 1 D Engine Rieju 0 2 d C BU Stort the rocket 2 4 08 RIEJU S A c Borrassa 41 1 7600 FIGUERES GIRONA SPAIN Telf 34 972500850 Fax 34 972506950 WWW e mail Qriejumoto com
3. Clutch control Oil pump control Headlinght height Clean and adjust Carburettor Vehicle test Road test Arter 1000 OR 3 MONTHS EVERY 5000 km 10 000 10 000 10 000 Engine Rieju 2 7 PARTS AND THEIR TORQUE WRENCH SETTINGS N O U A N POSITION Spark plug Cylinder head Cylinder head Cylinder head Countershaft Water cooling head Water pump body Pipe coupling Water pump body Water pump body Oil pump Oil pump lid Intake manifold Crankcase Cover clutch side Crankcase flywheel side Crankcase clutch side Crankcase flywheel side Crankcase clutch side Cover clutch side Cover flywheel side Primary gear Clutch side Clutch boss Disc boss clutch Disc pusher clutch Selector Magneto flywheel Magneto flywheel PART NAME Spark plug Nut Pipe fitting Temperature probe Hex nut T C B screw T C C E screw T C C E screw T C C E screw T C B screw T C C E screw T C C E screw T C C E screw Stud bolt T C B screw T C C E screw Hex screw Neutral indicator light Hex screw T C C E screw T C C E screw Nut Hex screw T C C E screw Hex nut Clutch adj screw Hex nut Screw Hex nut SCREWS 14 1 25 M7 M8 x 1 25 4 1 25 12 0 7 6 x 6 6
4. spacer 2 11 clutch gear 3 11 shim washer 1 12 tapered washer 2 F 12 paying attention to the direc tion in which they are assembled so as to reassemble them correctly afterwards 13 USING the magneto flywheel locking wrench 1 13 lock the flywheel and slacken the retaining nut of the gear on the countershaft with the wrench 1 14 14 REMOVE the gear on the countershaft 1 14 and the key Engine Rieju Engine 15 UNSCREW the nut 2 14 with a 19 mm wrench whilst holding the flywheel in place with the special wrench then remove the following parts in this order drive pinion countershaft drive gear key spacer bushing and O ring 16 BLOCKING the rotor of the magneto flywheel with the special locking wrench 1 15 unscrew the rotor retaining nut with a 15 mm wrench 17 REMOVE the rotor of the magneto flywheel by means of the appropriate puller 1 16 which must be screwed into the threaded seat of the rotor whilst holding the latter in place with a wrench turn the centre screw 18 REMOVE the stator by undoing the screws that secure it to the plate 1 17 19 TAKE the stator plate OUT of its seat by removing the 3 screws that secure it to the crankcase 2 F 17 and remove the key 3 F 17 JA P j p 4 gt Engine Rieju Engine 20 DISASSEMBLING the thermal section a unscrew the 4 cylinder head holding nuts and remove the relevan
5. 56 on the last disc using the spe cial wrench 2 F 56 Tighten the nut Cs 2 6 2 8 kg m 19 BEFORE fitting the starter assembly version without an electric starter make sure that the phase between the pawl on the sliding rod and the hole for fixing the spring is the same as before disassembly 90 57 20 FIT the starter assembly whilst hooking the spring to the hub on the cover 21 FIT the dowel bolts and a new gasket on the crankcase the clutch cover if necessary this operation can be made easier by turning the impeller of the water pump Secure in place with screws Cs 1 0 1 2 kg m If you have disassembled it refit the oil pump making sure that the O ring is in working order 1 58 ANI When refitting take care not to damage the oil pump gear Whilst fitting the starter lever its shaft turn it 180 counter clockwise and secure place with the fixing screws Cs 2 9 3 0 kg m F 58b This operation must be performed to pre load the return spring Engine Rieju 22 Before assembly CHECK the condition of the cage on the piston and its rollers Fit the piston making sure that the arrow marked on the top is facing towards the ex haust side F 59 and therefore towards the piston pin and its circlips 23 In the order indicated FIT the piston rings making sure that the ends are correctly positioned in the seats on the piston a new cylinder gaske
6. S A recommended spark plugs When replacing exhausted spark plugs visually inspect spark plug condition as described above to ascertain whether or not the engine is running properly ENGINE REMOVAL e For removal of the engine from the chassis refer to the Chassis Workshop Manual which lists all the operations required ENGINE DISASSEMBLY The manufacturer declines all responsibility for damage of any kind caused by disassembly and reassembly of the engine and its parts if unsuitable tools are used Use only ORIGINAL RIEJU SPARE PARTS Engine RIEJU Engine Rieju 2 1 EQUIPMENT KIT Code RIEJU 0 000 640 9999 2 2 LUBRICANTS LUBRICANTS TABLE 1 Synthetic mix oil 2 Gearbox oil SAE 10W30 type SE 3 Grease for moving parts Engine Rieju 2 3 DISASSEMBLY OF THE ENGINE After removing the spark plug and carburettor proceed as follows I DRAIN the engine oil by removing the relevant drain bolt 2 UNSCREW the coolant drainage screw 1 1 remove the water pump cover by undo ing the two fixing screws 2 1 Pay attention to the dowel bolts 1 2 3 UNDO the fixing screws of the flywheel cover left hand side and remove it Remove the starter motor if fitted by removing the two screws on the crankcase and the screw on the support strap 4 Take the carburettor out of its seat remove the intake union and the relative clutch brid ge remove the plate gro
7. idle position of the lever otherwise make any necessary adjustments by means of the adjustment screw Engine Rieju Engine 2 4 GENERAL WARNINGS ZN Before reassembling the engine either totally or partially thoroughly clean the parts by washing them with petrol drying them with compressed air and making sure that they are sufticiently oiled and in perfect working order t is always advisable to replace the gaskets because old ones be leaky We recom mend you always replace the engine oil seals they may have been damaged during disas sembly and this could adversely affect engine operation Always use the special plugs to ensure correct assembly of the oil seals A Secondary gear shaft oil seal Secondary gear shaft oil seal assembly plug B Connecting rod oil seal Connecting rod oil seal assembly plug clutch side Connecting rod oil seal assembly plug flywheel side C Clutch lever oil seal Clutch lever oil seal assembly plug D Shift shaft oil seal Shift shaft oil seal assembly plug E Water pump oil seal Water pump oil seal assembly plug Check carefully that the pieces are whole and arrange all the various groups of gears in such a way that assembly may be carried out correctly Engine Rieju Engine 1 WASH the two crankcases and the bearings with petrol and blow them with compres sed air checking
8. 1 50 using the special plug 2 F 50 2 The O ring 1 51 3 The spacer 2 51 with the bevelled side facing the crankshaft Push in place until it stops Now fit the key 1 52 the countershaft drive gear 2 F 52 the drive sprocket and the nut Cs 6 7 7 5 kg m Fit the key and driven gear on the countershaft 2 F 53 making sure that the reference notches on the two gears match F 53 Tighten the nut Cs 4 5 5 0 kg m apply Loctite 242 f 9 Engine Rieju 14 PROCEED in reverse order Refit the clutch assembly and remember to replace the nut fixing washer with a new one fit the clutch boss fixing nut Cs 5 5 6 0 kg m and bend the tab 15 FIT the following components on the output shaft in the order given clutch rod grea se beforehand ball and disc pusher 16 FIT the clutch disc assembly in the order shown in F 54 the iron discs 1 2 3 54 should be fitted with the notch highlighted by the arrows at 120 the one from the other starting from the notch facing upwards on the first disc Fit the last clutch disc making sure it is timed with the boss F 54b Engine Rieju Engine 17 FIT the springs and fixing screws and tighten Cs 0 3 0 5 kg m 18 Correct operating position of the clutch is obtained when the lever in the position indicated by the arrow F 55 is parallel to the cover resting surface To obtain this condition turn the adjustment screw
9. 4 4 ndi Engine workshop manual Engine INTRODUCTION NOTES FOR EASY CONSULTATION 6 GENERAL WORK PROCEDURES 7 RECOMMENDATIONS 8 SPARK PLUGS 10 ENGINE RIEJU EQUIPMENT KIT 14 LUBRICANTS 14 ENGINE DISASSEMBLY 15 MAINTENANCE 22 ENGINE ASSEMBLY 26 ENGINE SERVICINGAND COMMISSIONING SCHEDULE 33 PARTS AND THEIR TORQUE WRENCH SETTINGS 34 EXPLODED VIEW OF THE ENGINE AM6 EURO2 35 Were Introduction Engine All checks maintenance repairs or replacements etc the vehicles manufactured laguti are to be performed by skilled and expert technical personnel with specific experience in sta te of the art technology and full knowledge of the quickest and most rational procedures technical characteristics setting values and tightening torques which may only be properly and exhaustively provided by the manufacturer This set of WORKSHOP MANUALS concerning two stroke engines provides technicians of the sector Authorised Service Centres etc the essential information for operating in accordance with the latest good working practices and work safety regulations These publications provide all necessary information for routine procedures on all the RIEJU motor vehicles equipped with two stroke engines currently in production at the date of issue The information provided deals with the motor vehicle ENGINES Some basic technical information has been inten
10. ats and apply grease to prevent them falling out 2 PREPARE the transmission assembly primary secondary keeping all components to gether F 36 Put a 0 6 mm shim washer under the gear and position the fork in the 3ra and 4 primary gear F 36 LOWER the assembly thus formed into its seats F 37 Raise the 5 nspeed gear on the secondary shaft and insert the fork F 38 Fit the other fork speed gear into its seat F 39 Engine Rieju Engine 3 FIT desmodronic shaft 40 Insert the fork guide pins into the desmodronic shaft 41 Fit the fork guide rod into its seat 42 Turn the desmodronic shaft until it reaches the position shown in the figure F 43 N B these operations must be effected without forcing with a hammer or other tools Engine Rieju Engine 4 INSERT the shift shaft with the lower washers 0 6 mm thick 1 44 and insert the return spring hooks in the relevant anchoring bridge F 45 then check that By putting the desmodronic shaft in 3ra speed make sure the rollers of the cam at an equal distance from the fork hooks On the contrary slightly bend the ends of the spring until obtaining the requested condition 5 FIT the countershaft in the clutch crankcase N B assembly of the countershaft in its seat implies no interference 6 If it has been removed FIT the connecting rod in the crankcase on flywheel s
11. e correct torque In any case when using an adjustable wrench take care to proceed as shown in Figure l 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 Engine 1 4 WARNINGS 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 attained 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 a comfortable position and ensure that the vehicle is stable Never use a screwdriver as a lever or chisel Never use pincers to loosen or tighten screws or nuts because in addition to not providing a sufficient clamping force they may also damage the screw head or nut hexagon Never tap the w
12. ide using the tool 1 46 keep the connecting rod at the T D C whilst tightening the screw until the connecting rod touches the bearings 7 FIT the dowel bolts 1 2 F 47 apply gasket paste on the mating sides of the crankcases F 47 and oil all shafts Place the crankcase flywheel side over the other crankcase and tap gently all over with a wooden leather or plastic mallet until the crankcases are joined 8 FIT the 13 fixing screws and tighten in place Cs 1 0 1 2 kg m Make sure all shafts can turn freely Make sure that none of the shafts feature excessive end play in which case separate the crankcases and replace the top shim washer with another having a more sui table thickness 9 FIT the new oil seals using the specific plug for each Engine Rieju Engine 10 FIT the key for the magneto flywheel put the stator its seat and fasten in place with the fixing screws Cs 0 25 0 3 kg m Fit the rotor and tighten the nut Cs 4 3 4 5 kg m using the usual wrench F 48 11 FIT the sprocket snap ring 1 49 sprocket 2 snap ring 1 fit the clutch control pin 3 F 49 with its return spring 4 F 49 12 CHECK operation of the sprocket and gear wheel pair If any of the gears needs to be replaced it is recommended to replace the pair since this will ensure smoother and quieter operation 13 FIT the crankshaft clutch side in the following order 1 The overturned oil seal
13. ity 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 P TOXIC Indicates a possibility of intoxication or inflammation of the upper respiratory za tract 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 ENGINE 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 Figure Tightening torque Page Paragraph Section Diagram Table Screw 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 component described and illustrated Letters not followed by a number indicate a single screw In case of different screws being referred to in the illustration the letter Tr is followed by a number and a small lette
14. m the other one parallel and the other perpendicular to the axis of the piston pin F 33 The maximum permissible ovalisation is 0 03 mm exceeding which the cylinder must be replaced Engine Rieju Engine Repeat the measurements several positions along the cylinder jacket between the top face of the cylinder and the exhaust gap 34 Then check the diameter of the piston and compare it with that of the cylinder F 33 POSITION THE THERMOSTAT HOLE ASSHOWN The maximum end float is 0 10 mm exceeding which the piston should be replaced See the chart below COUPLING CHART e MIN MAX PLAY TOLE PISTON TOLE CYLINDER SELECTION AM6 50 WATER COLLED 0 049 0 063 0 057 0 007 0 002 0 056 0 050 0 001 0 006 CYLINDER IN GHISA 0 049 0 043 0 007 0 012 CAST IRON CYLINDER Important maintain the same identification letters on the cylinder and piston The cylinder identification letter can be found on the flat surface of the oiler 10 WATER PUMP a Place the clutch crankcase right hand side on a flat surface b Fit the oil seal in the right direction as shown F 35 c Fit the impeller gasket dowels and water pump cover Engine Rieju Engine 2 5 ENGINE REASSEMBLY E PLACE the clutch crankcase right hand side on flat surface Then fit the spring and the gear selection poppet ball in their se
15. r for instance Tr4a Unless otherwise specified units and components are reassembled by pro ceeding the reverse order of removal OPERATIONAL SYMBOLS L Loctite O Oil lubrication y pt Greasing p Introduction Engine 1 3 GENERAL WORK PROCEDURES 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 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 be used as the movable jaw tends to open thus risking damaging or not properly tightening the bolt to th
16. ral condition of the engine A light brown colour of the insulator indicates that engine working conditio ns are generally correct Sooty black deposits that are dry to the touch and opaque are a sign that working temperature is too low i e that the heat range of the spark plug is too high mixture too rich or ignition defective whitish colour of the insulator is indicative of too lean a mixture or of too low a heat range of the spark plug i e spark plug too hot Check electrode gap F 6 even if the spark plug is new by means of a calibrated thickness gauge necessary adjust by acting only on the earth electrode Pr Tr Nm 6 Introduction Engine SPARK PLUG MAINTENANCE Spark plug maintenance consists essentially of a periodical visual inspection Remove the spark plug and check for proper condition and gap Clean the electrodes and the insulator thoroughly by means of a wire brush Remove any residual dirt with a strong jet of compressed air Lubricate spark plug thread with engine oil or graphitised grease and install it by hand until finger tight Tighten to the specified torque with a spark plug wrench see F 6 It is imperative that any spark plug exhibiting cracks on the insulator or corro ded electrodes be replaced SPARK PLUG REPLACEMENT 5000 km Upon prescribed mileage being reached always replace the spark plug Use RIEJU
17. remaining fork and raise F 26 paying attention to the shim washer un der the secondary shaft 28 REMOVE the equaliser countershaft pull the connecting rod from the crankcase on clutch side if necessary tap gently with a plastic or rubber mallet paying attention not to damage the thread N B as far as the clutch crankcase side is concerned the crankshaft and countershaft do not interfere with each other 29 Bearings should only be REMOVED if they need to be replaced i e they are worn or their ser vice life has ended Engine Rieju Engine 30 IF the pump needs to be replaced proceed as follows 27 a Detach the oil pump supply pipe 1 and put a plug into it to prevent oil leaks b Detach the oil delivery pipe leading from the pump to the carburettor 2 c Disconnect the control cable fastened to the pump s lever 3 d Undo the pump fixing screws 4 and remove the pump e Fit the new pump in its seat and replace the O ring f Plug the oil delivery pipe 2 into the new pump g Plug the oil supply pipe 1 into the pump h Take the purge screw and gasket off the pump 5 and let the oil containing air bubbles leak out Wait until only oil is leaking out Purging can thus be considered accomplished You can now refit the screw in place 1 Reconnect the control cable 3 to the pump lever making sure that the idle position of the throttle grip on the handlebar corresponds to the
18. rench with a hammer or other similar tools to loosen or tig hten screws and nuts F 2 Never attempt to increase the lever arm by fitting a tube into the wrench F 3 Introduction Engine 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 point solvents to clean the vehicle components 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 The front wheel should preferably anchored to the equipment 4 integral with the lifting board F 4 Introduction Engine 1 5 SPARK PLUGS Insulator 2 Body 3 Gasket 4 Electrode 5 Earth electrode 6 Threads SPARK PLUG CHECK 1 000 km Remove the spark plug while the engine is hot taking utmost care to avoid scalding he carbon deposits and the colour of the insulator around the central electrode provide good information as to the heat range of the spark plug and to carburetion lubrication and gene
19. t the cylinder the centre cylinder O ring in the stud bolts the O ring on the cylinder head the head clean beforehand Tig hten the nuts evenly and diametrically Cs 1 4 1 6 kg m check the position and tightness of the O ring on the cylinder head 24 FIT the reed valve F 60 followed by the exhaust manifold tightening the four screws evenly and diametrically Cs 0 9 1 1 kg m 25 REFIT the flywheel cover a new gasket and its fixing screws which must be tightened Cs 0 1 0 2 kg m 26 REFIT the oil drainage bolt replace the gasket and secure firmly in place Cs 1 7 1 8 kg m 2T POUR oil into the engine 0 750 kg through the hole at the top Engine Rieju Engine 2 6 ENGINE SERVICING AND COMMISSIONING SCHEDULE MAINTENANCE OPERATIONS Check Adjustment of engine idling speed Gas and oil pump control Front and rear brake control Operation of the electrical equipment Petrol ducts Oil ducts Front and rear brake liquid ducts Coolant duct Fuel heating duct Tire pressure Tire condition pressure and wear Level of front and rear brake liquid Level of coolant Level of battery electrolyte Screw tightness Battery charge level Replace Air filter filtering element Front and rear brake pads Gearbox oil Chain pinion gear wheel Clutch discs Spark plug Check and or replace Piston Cylinder head Discharge gap Check and lubricate Chain tightness and condition Check and adjust
20. t washers remove the head its O ring the cylinder the cylinder gasket and the four O ring on the stud bolts CAUTION before removing the circlips of the piston pin put a clean cloth into the opening on the crankcase to prevent the circlips dropping into the engine 21 REMOVE the two circlips F 18 remove the piston pin and if you intend to use a 2 diameter plug knock gently taking care to hold the piston on the opposite side in order to avoid damaging the connecting rod 22 REMOVE the 13 screws joining the two crankcases 19 and take the clutch pin out of its seat 5 DO i 23 SEPARATE the 2 crankcases gentling tapping the secondary shaft and shift shaft with a wooden mallet IMPORTANT if you need to take the crankshaft out of its seat use the spe cial tool 1 F 20 24 Once the crankcases have been separated CHECK that the shim washers are on the shafts and not on the crankcase that has just been removed F 21 Engine Rieju Engine 25 PUT the neutral signal in the position shown the photo 22 hence remove the shift shaft and its relevant lower shim washer 1 23 26 PULL OUT the fork guiding rod and remove the top fork F 24 to take the fork out of its seat remove the desmodronic shaft F 25 and raise the gear on the secondary shaft carrying the forks 27 PUT the following components TOGETHER output shaft secondary shaft and
21. that the bearings run freely and noiselessly CAUTION if it should be necessary to replace a bearing the seat must be heated before installing the new bearing 2 MAKE SURE the connecting rod is in perfect working order and check for faults espe cially in the bearing seats Make sure assembly on flywheel side has been properly accomplis hed Using a comparator check the eccentricity of the two connecting rod axle shafts The maximum eccentricity value must not exceed 0 04 mm On the contrary centre accordingly Make sure the connecting rod is perpendicular 3 MAKE SURE the transmission is in perfect working order and fit the shim washers in the right positions If you have replaced components make sure that they are put in the same positions as the parts removed and that the end float does not exceed 0 1 mm To obtain this condition measure the distance of the shim washers on the crankcase and com ponents and fill any gaps with other shim washers as shown in the photo F 28 4 CHECK the distance of the shim washer of the desmodronic shaft both on the crankcase and on the part and fill any gaps with other shim washers as shown in the photo F 29 The end float must be less than 0 1 mm 0 6 5 CHECK the distance of the shim washers of the shift shaft both the crankcase and on the part and fill any gaps with other shim washers as shown in the photo F 30 The end float must be less than 0 1 mm Sp 0 6
22. tionally omitted as it is considered to be common knowledge Additional information is available in the SPARE PARTS CATALOGUES of each model It is important that before referring to the specific engine manual the information given in this general section be carefully read as it provides all the essential hints and guidelines for best consulting the various topics and main technical subjects Note These manuals provide the necessary information and instructions for routine maintenance and servicing This information has been given to us by the engine manufacturers We therefore decline all responsibility for any error omission or misrepresentation RIEJU reserves the right to make any changes and modifications hereto it deems necessary without prior notice For further information and details please contact the RIEJU S A Service Division 1 1 MANUAL UPDATES The updates will be sent by us in a reasonable time Every Cd Rom you will receive will super sede the one already in your hands The table of contents will be duly updated in the event that new pages are inserted which ren der the consultation of the manual difficult IMPORTANT The Workshop Manuals are to be considered as essential tools to be properly kept up to date so as to maintain their validity over time Introduction Engine EDITING SYMBOLS CAUTION Recommendations and precautions regarding rider safety and motor vehicle integr
23. up 1 3 5 REMOVE the sprocket 1 4 by removing the snap ring 2 F 4 using ring pliers remove the sprocket by hand and remove the other snap ring underneath the sprocket Engine Rieju 6 REMOVE the sliding stop screw for starting from clutch side 1 5 7 REMOVE the fixing screws of the plastic oil pump cap 6 Undo the screws securing the oil pump to the cover then remove the pump 8 REMOVE the cover crankcase fixing screws of which one M6x55 2 F 6 that secure the water pump cover and the relative clutch cover to the crankcase now remove the cover 3 F 6 and its gasket 9 TAKE the starter assembly OUT of its seat only for versions with starter pedals bearing in mind that the any shim washers must be put in the same position when the com ponent is reassembled CAUTION when disassembling this group carefully check the position of the pieces so as to reassemble them correctly afterwards 10 UNDO the screws compressing the clutch springs 1 7 then remove the clutch pla te 2 F 7 and the entire set of discs 3 F 7 remove the disc pusher the ball and the clutch rod 2 3 F 8 which are housed in the centre hole of the change shaft Engine Rieju DISENGAGE the nut from its fixing tab 1 9 using the appropriate wrench 1 10 unscrew and remove the fixing nut 2 F 10 of the clutch boss 12 REMOVE the following pieces in this order clutch boss 1 11
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