MRX-SMX ANG.indd
Contents
1. Rieju chassis Chassis 46 BRAKE MASTER CYLINDER Remove the rear brake master cylinder cover taking the 2 bolts out A F 79 To remove the master cylinder is necessary to disconnect the STOP switch lead B F 80 and unscrew it Remove the clamp C F 80 of the brake fluid delivery pipe and empty it in a tray ATTENTION Brake fluid is abrasive 47 KICK STARTER Unscrew the nut A F 81 and pull the lever to remove it ATTENTION The assembly in a different position from the original one can reduce the stroke when starting Rieju chassis Chassis 48 SWING ARM Remove the chain the rear brake caliper the rear wheel and the shock absorber Unscrew the nut A F 82 and remove the axle on the right side Rieju chassis 49 PARES DE APRIETE TORQUE TABLE Element Chassis Front wheel bolt Front wheel lock bolt Rear front bolt Front Rear brake caliper Muffler Lateral coupling of the exhaust muffler Engine fixing screws Handlebar control screw Shock absorber screws Fork bolt Handlebar fixing bolt Steering top nut Steering middle nut Swing arm bolt FB 8 Grease2. Clutch type Primary transmission Clutch crown wheel Drive pinion Transmission ratio Secondary transmission Engine output pinion Drag plate Transmission ratio Chain Chassis CASTROL MTX SAE IOW 40 820 c c Wet type foam rubber cartridge 95 Unleaded petrol 8 4 L Dellorto PHBN 16 HS NGK BR 9 ES 0 6 0 7 mm Wet multiple disc 2 2 52 4 36 420 x 126 steps GEARCHANGE Primary shaft Secondary shaft Gear ratio Output ratio Z 12 Z 36 3 00 10 65 Z 16 2 33 2 06 l 7 3 Z 19 Z 29 2 22 2 27 1 23 4 37 2 24 2 25 1 04 3 69 Z 25 Z 24 1 53 5 43 0 96 3 40 Rieju chassis Suspension Front Rear Suspension Front Brakes Front Rear Brakes Front Rear Tyres Front Rear Tyres Front Rear Electric equipment Ignition system Generator Ignition advance Bulb voltage and wattage Headlight Taillight Dashboard Turn signal lights Odometer lighting Chassis MRX SMX MRX SMX Inverted hydraulic fork 35 mm CASTROL OIL FORK I5W 20 245 cc per bar Hydraulic damper MRX PRO SMX PRO PAIOLI Inverted hydraulic fork 38 mm CASTROL OIL FORK 10W 325 cc per bar Gas filled damper and spring preload adjustment MRX SMX Disc Y 260 mm Disc Y 200 mm MRX PRO SMX PRO Wave typ
3. 37 FRONT WHEEL ATTENTION Loosen the fixing bolt A F 67 of the axle lo cated at the fork Unscrew the wheel axle and remove it Rieju chassis Chassis 38 ODOMETER SENSOR A ATTENTION Loose the fixing bolts of the axle located at the fork A F 68 Remove the front wheel Move the front wheel axle away till be able to remove the odometer sensor B F 69 68 39 FRONT BRAKE DISC Remove the front wheel Unscrew the bolts A F 70 that fix the disc 40 STEERING Unscrew the 4 bolts A F 71 of the handlebar Loosen the 2 lateral screws B F 71 to facilitate its removal Extract the top nut C F 71 and remove the top plate To extract the axle unscrew the nut D F 71 Para extraer el eje desenroscar la tuerca D F 71 Rieju chassis Chassis 41 FRONT FOOTREST Unscrew the bolt A F 72 holding the lower nut ATTENTION Take into account the position of the spring for the later assembly SMX version 42 REAR FOOTREST Unscrew the bolt A F 74 holding the lower nut 43 REAR BRAKE LEVER Unscrew the bolt A F 75 Rieju chassis Chassis 44 DRIVE CHAIN GUARD Unscrew the 2 bolts A F 76 and remove the guard 45 TRANSMISSION CHAIN Remove the 2 fixing screws A F 77 from the guard and take it out Extract the securing clip B F 78 of the link and remove it Chain tensioning see page 26
4. Then 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 17 GEAR LEVER Unscrew the fixing bolt A F 30 After pull carefully the lever in order not to damage the grooved shaft Rieju chassis Chassis 18 ECU UNIT Remove the seat and the fuel tank only move it away Unscrew the 2 fixing bolts A F 31 and then disconnect the main wiring 19 OIL TANK Remove the seat the left front lateral cover and disconnect the level sensor wire and the oil filter Unscrew the 2 bolts A F 33 that fix the tank to the chassis and remove it ATTENTION Before disassembly empty the oil tank through the filter hole Rieju chassis ie iu i Chassis 20 OIL LEVEL SENSOR WIRE Remove the seat the left front cover the level sensor wire and the oil filter Unscrew the 2 bolts that attach the tank to the chassis and remove it 21 OIL FILTER Remove the left front cover Loosen the hose clamp and the clamp that hold the filter onto the oil tank To extract it pull it outward ATTENTION Place tray under the tank to collect the oil Rieju chassis Chassis 22 FUEL TANK Remove the seat and the front lateral covers ATTENTION Before disassembly close the fuel
5. INTHE MANUAL Ap Figure Tightening torque 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 follo wed 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 a small letter for instance Tr4a Unless otherwise specified units and components are reassembled by pro ceeding in the reverse order of removal Introducci n 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 When tightening screws or nuts start with the larger diameter or inner fastene
6. MAIN PARTS Left side IDENTIFICATION OF THE MAIN PARTS Right side Headlight 2 Oil mixing tank 3 Battery SMX 4 Gear pedal 5 Radiator 6 Tool box 7 Fuel tank cap 8 Rear brake pedal 9 Passenger footrest 10 Number plate light and plate holder Rieju chassis Chassis CONTROLS Controls Instruments Main switch Clutch lever Turn signal switch Dashboard Start lever Front brake pump Front brake lever Accelerator grip 9 Horn switch 10 Lights switch Dipped and full beam headlights a me Ona uh won y KEYS e 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 e 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 SIDE STAND e Make sure that the side stand is well fixed and it moves correctly likewise it is advisable to check frequently the hold up system made up of drive springs Rieju chassis Chassis DASHBOARD Steering warning light This warning light twinkles when the steering switch moves towards the left or the right 2 Coolant temperature warning light This warning light lits when the temperature of the coolant is too much high If this happens stop the eng
7. 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 Andcontrol there is enough oil for the front brake observing by the peephole placed in the pump Change For the front brake remove the cover A F 16 after taking the screws out B F 17 For the back brake remove the C F 17 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 fluid DOT 4 ATTENTION Brake fluid 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 18 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 lead Rieju chassis Chassis TENSION ADJUSTMENT OF THE TRANSMISSION CHAIN One of the special features of the models MRX SMX is the assembly of a chain tensor in such a way that maintain always this element in corre
8. MRX SMX 20 Chassis workshop manual Chassis INTRODUCTION MANUAL UPDATES SYMBOLOGY USED IN THE MANUAL ABBREVIATIONS USED IN THE MANUAL GENERAL WORK RULES RECOMMENDATIONS CO GETTING TO KNOW THE MOTORBIKE MAINTENANCE OPERATIONS TECHNICAL SPECIFICATIONS UNPACKING APPARANCE DATA FOR IDENTIFICATION ANTI TAMPERING LABEL IDENTIFYING THE MAIN ELEMENTS CONTROLS KEYS STEERING LOCK SIDE STAND INSTRUMENT PANEL TYRES CHECKING TYRE PRESSURES FUEL TANK COOLANT REPLACING COOLANT ENGINE OIL TRANSMISSION OIL BRAKE FLUID ADJUSTING THE MINIMUM REV SETTING ADJUSTING TRANSMISION CHAIN TENSION 15 15 18 18 Chassis DISASSEMBLY 1 N N 0 O N YN N N YN YN FA a a A A A J O O N O Aa RA O N gt O REAR VIEW MIRRORS FRONT HEADLIGHT HOLDER FRONT SIDE COVERS SEAT NUMBER PLATE HOLDER REAR COVER FRONT MUDGUARD FUEL TANK FUEL TANK PROTECTOR HANDLEBARS STEERING CLUTCH LEVER FRONT BRAKE CYLINDER FRONT HEADLIGHT FRONT INDICATOR LIGHTS REAR LIGHT REAR INDICATOR LIGHTS INSTRUMENT PANEL TURN INDICATOR REGULATOR CONTACT RELAY CONTROL UNIT CDI BATTERY OIL SENSOR OIL TANK AIR FILTER FUEL TRANSMISSION OIL MIXER AIS SYSTEM EXHAUST SILENCER RADIATOR CARBURETTOR GEAR CHANGE LE
9. VER REAR BRAKE LEVER SIDE STAND 28 28 29 29 30 30 30 31 31 32 92 33 33 34 34 35 35 36 36 37 37 38 38 38 39 39 39 40 40 41 41 42 42 43 Chassis 35 36 37 38 39 AO 41 42 43 44 45 46 47 48 48 REAR BRAKE CYLINDER REAR BRAKE CALLIPER ENGINE REAR WHEEL CHAIN PROTECTOR DRIVE CHAIN SHOCK ABSORBER SWING ARM FRONT WHEEL FRONT BRAKE CALLIPER FRONT BRAKE DISK SPEED SENSOR FRONT FOOTRESTS REAR FOOTRESTS BRACKETW TIGHTENING TORQUES 43 43 44 45 45 45 46 46 47 47 47 48 48 48 49 Introduction EPEE E Introducci n 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 prev
10. ain The chain is composed of lots of pieces that work together A correct maintenance of the chain is required to avoid a quickly wear so therefore it is convenient to grease the chain periodically with a special oil for this purpose Before lubricating it is necessary to clean the chain in order to get the dirt off Clean with a brush or a cloth and then apply the lubricant between the lateral plates and in all the central rollers 5 Rieju chassis Chassis Unscrew the nut A F 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 2 REAR LATERAL COVERS Remove the seat Unscrew the 3 bolts A F 3 Following pull the part to remove it 3 PILLION SEAT Remove the seat and the rear cowlings Unscrew the 2 bolts A F 4 holding the 2 nuts B F 5 of the lower part a yp gt E gt gt 7 Rieju chassi chassis Chassis 4 FRONT LATERAL COVERS Remove the seat Unscrew the 3 bolts A F 6 from both sides and the bolt on the front 5 MUFFLER Remove the seat and the left rear cowling Loosen the clamp A F 8 of the exhaust which holds the muffler Following unscrew the 2 bolts B F 9 that fix the muffler to the chassis To extract it pull the muffler backwards ATTENTION Before proc
11. ast Rieju chassis Chassis 26 RADIATOR Remove the seat the front lateral covers Empty the cooling circuit loosening the drain screw A F 49 Unscrew the 2 bolts B F 50 that hold the air intake radiator Loosen the clamps that hold the engine hoses to the radiator 51 After unscrew the bolt D F 52 that attach the radiator to the chassis and remove it pulling upwards 27 SIDE STAND A ATTENTION Hold the motorcycle before carrying out Remove the tensioning spring A F 53 Following unscrew the nut B F 53 holding the screw on the inside Rieju chassis Chassis 28 FRONT TURN SIGNALS Unscrew the bolt holding the nut on the inside After turn the light off in the wiring ATTENTION Pay attention to the position of the leads for the later assembly 29 FRONT MUDGUARDS Unscrew the 4 bolts A F 56 located at the lower part of the mudguards Rieju chassis Chassis 30 HEADLIGHT Loosen the 4 rubber clamps that hold the headlight cover to the front fork To facilitate the task tilt the headlight Unscrew the 2 bolts A F 58 that fix the headlight to its cover After remove the rubber from the headlight cover and disconnect the leads Al ATTENTION Pay attention to the lead position for the later assembly 58 31 DASHBOARD Loosen the 4 rubber clamps of the headlight cover and tilt it to facilitate the
12. cock Extract the vent tube Unscrew the 2 bolts A F 40 that fix the tank to the chassis Following remove the tank pulling it upwards Rieju chassis Chassis 23 TRANSMISSION OIL MIXING Unscrew the 2 bolts of the cover Move the tensor backwards and remove the throttle cable 24 CARBURETTOR Remove the seat the front cowlings and the fuel tank only move it away Cut the hose clamp that hold the carburettor onto the filter box Unscrew the top cover of the carburettor and extract it Likewise 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 Chassis 25 ENGINE Remove the seat the front and rear lateral covers the fuel tank and the transmission chain Disconnect the 2 tubes of the cylinder head heater unscrew the bolts of the air intake tube A F 46 and separate the join from the spark plug Disconnect the thermocontact lead Disconnect the neutral gear lead located at the lower part of the engine the flywheel Magneto lead and the ECU leads Unscrew the bolts of the oil mixing cover and disconnect the transmission Empty the cooling circuit by loosening the drain screw B F 47 Disconnect the hose of the cylinder head radiator C F 47 and pump radiator Remove the 3 lock nuts and the 3 screws D F 48 that fix the engine ATTENTION Screw the bolt of the front the l
13. ct tension To correct the chain tension work on the eccentrics A F 19 of the rear wheel axle trying to operate always on the point of maximum chain tension Turn the rear wheel trying to work the tension in different points to find the tensest point pulling down to avoid opera tion during the check 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 Get a perfect balance and alignment of the wheel The eccentrics grooves can be of help to achieve it leave the eccentrics in the same position in both sides of the swing arm To control and adjust the chain you should operate on the rear 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 different places to meet the tensest point The moped should be placed vertically with the two wheels on the floor and the looseness of the chain ought to be from 30 to 40 mm The adjustment of the chain tension carries out loosening the rear axle of the wheel and screw in or unscrew the adjacent bolts and nuts B F 21 always getting the same distan ce on both sides of the axle A wrong alignment of the chain and the wheel can make the chain comes out as well as give stability problems in the motorcycle It is necessary a periodically cleaning and greasing of the ch
14. e Disc 260 mm Wave type Disc 200 mm PRO 80 90 21 con c mara 1 7 kg cm 110 80 18 con c mara 1 8 kg cm SMX SMX PRO 100 80 17 con c mara 1 8 kg cm 130 70 17 con camara 1 9 kg cm2 Electronic 12V 95W Ducati 20 1 4 mm before the P M S 12V 35 35 12 21 5W 12V 1 2W 12V 12V 1 2W 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 e The data for identifying the engine A F 1 are on the right sump Vehicle identification number The identification number of the motorcycle 2 is stamped on the steering pipe This identification number is used to identify the moped SAFETY TAG It contains the identification data of the motor cycle according to the 97 24 CE guidelines 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 It is located in the left side of the chassis close to the steering pipe Rieju chassis Chassis IDENTIFICATION OF THE
15. eeding to the muffler disassembly make sure that it is cooled down Rieju chassis Chassis 6 EXHAUST Remove the seat the left rear cowling and the muffler Loosen the clamp A F 10 of the exhaust which holds the muffler Remove the 2 springs B F 11 that hold the exhaust onto the engine in the front part and the Silembloc bolt 11 Following remove the vent tube AIS system D F 12 and the exhaust pulling it forward ATTENTION Before proceeding to the muffler disassembly make sure that it is cooled down 7 AIS SYSTEM SECONDARY AIR VALVE Loosen the clamps A F 13 Unscrew the 2 fixing bolts B F 13 QA While p Rieju chassis Chassis 8 BATTERY SMX Remove the seat Disconnect the two leads positive red and negative black Remove the rubber parts and then the battery pulling it upwards 9 REAR TURN SIGNALS Cut the clamp that hold the leads and disconnect them from the main wiring Following loosen the screw A F 17 and pull the lead 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 Rieju chassis bed ad Chassis 10 TAILLIGHT Cut the clamp that hold the leads and disconnect them from the main wiring After loosen the 2 screws A F 9 that attach the light to the fender To ex
16. ine immediately 3 N neutral gear warning light This warning light lits when the transmission is in the neutral gear position 4 Oil level warning light This warning light lits when the oil level is low 5 Warning light of the full beam headlights This indicator lits when the full beam headlights are in use Rieju chassis Chassis TYRES Dimensions 80 90 21 48 enduro front 110 80 18 58 P enduro rear 100 80 17 52 5 supermotard front 130 70 17 62 S supermotard rear PRESSURE CONTROL The pressure of the tyres must be controlled and regulated with the tyres at room tem perature FRONT 1 7 kg cm2 REAR 1 8 kg cm2 FRONT 1 8 kg cm2 REAR 1 9 kg cm2 F 10 FUEL TANK Unscrew the cap and refuel the tank paying attention not to pass the limit A F 11 if after filling some petrol residues are showed on the motorcycle wipe them off immediately Use normal unleaded petrol with a RESEARCH 95 octane number Fuel tank capacity Total 8 4 litres Rieju chassis Chassis COOLANT Control Remove the cap A F 12 with the engine cold and first release the residual pressure 2 Check the coolant level with the engine cold since it varies depending on the engine temperature The coolant level should fill the radiator panel 3 If the level is low add coolant 4 Put the cap again COOLANT REPLACEMENT Before carrying ou
17. ious 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 value over time if they are kept constantly up to date Introducci n Chassis SYMBOLOGY USED INTHE MANUAL CAUTION Recommendations and 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 SNO Indicates a possibility of intoxication or inflammation of the upper respiratory ob 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 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 Introducci n Chassis ABBREVIATIONS USED
18. motorbike Rieju chassis Chassis IST SERVICE 2NP SERVICE SER EVERY MAINTENANCE OPERATIONS 1 000 kms 3 000 kms 5 000 kms Brake system checking Transmission oil level checking Change Chain tension and wear inspection Suspension control Controls and cables checking adjustment and grease Wheel spoke tension and wheel off centre inspection Air filter cleaning and grease Carburettor checking and adjustment Spark plug checking and adjustment or change Screws and chassis nut control plastics Electrical system checking Segments wear control Radiator water level control Exhaust system checking Oil pump operation checking SPECIFICATIONS AND TECHNICAL CHARACTERISTICS Dimensions MRX SMX Overall length 2050 mm 1970 mm Overall width 790 mm 790 mm Overall height 1170 mm 1170 mm Seat height 920 mm 920 mm Wheelbase 1332 mm 1332 mm Minimum ground clearance 358 mm 358 mm Weight Dry Engine Type 2 stroke Transmission 6 speeds Make Minarelli Cylinder arrangement Monocylindrical forward inclined cylinder Cylinder capacity 49 7 c c Bore x stroke 40 3 x 39 mm Starting system type Kick starter and electric starter Lubrication system Wet sump Oil type CASTROL TTS injection 2 stroke oil Rieju chassis Transmission oil Type Quantity Air filter Fuel Type Tank capacity Carburettor Spark plug Type Electrode gap
19. ngine 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 wrench 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 Introducci n Chassis y 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 po point solvents to clean the vehicle components Never suck from or blow into the fuel pipe d 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 F 4
20. rs and tighten them in progressive pulls in accordance to a criss cross pattern Preferably use open end box wrenches by pulling and not pushing e 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 the correct torque In any case when using an adjustable wrench take care to proceed as shown in Figure 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 Introducci n 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 perfor med 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 e
21. t this operation place a tray under the tube Parking the vehicle on a flat surface and place a tray under the radiator 2 Drain the cooling circuit removing the drain plug A F 13 In case you need more coolant than usual to reach the indicated level or if you need to refill too often control the cooling circuit Rieju chassis Chassis ENGINE OIL Inside the tank there is an electronic sensor which lights up the red warning light of the reserve petrol tank on the dashboard when the tank shows low lubrication To refill the oil remove the cap A F 14 and fill very cautiously Recommended oil SYNTHETIC OIL FOR 2 STROKE ENGINES TRANSMISSION OIL Change Place the motorcycle flat surface 2 Warm the engine up for some minutes 3 Pull the engine up Place a tray for the oil under the engine and remove the drain plug C F 15 4 Unscrew the drain screw A F 15 and the screw B F 15 to allow the oil to flow 5 The drain screw tightly A F 15 6 Fill the engine with oil till it comes out by the level hole B F 15 Put the screw again in the hole B F 15 place the drain plug C F 15 and tighten it It is advisable to use SAE 40 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
22. task Disconnect the odometer lead A F 60 and the LEDs leads B F 59 Following unscrew the 2 top bolts C F 61 that fix the screen to the chassis Rieju chassi chassis Chassis 32 FRONT BRAKE MASTER CYLINDER Disconnect the micro switch terminals of the brake light Unscrew the join A F 62 that holds the hose onto the master cylinder After unscrew the 2 bolts B F 62 and remo ve the front brake master cylinder ATTENTION For the later assembly it is advisable to repla ce the copper gaskets and drain the circuit ATTENTION Brake fluid is abrasive 33 CLUTCH LEVER Disconnect the transmission from the clutch A F 63 and from the starter B F 63 After unscrew the 2 bolts C F 64 and remo ve the lever 34 HANDLEBAR Remove the controls from each end Unscrew the 4 bolts A F 64 and remove the handlebar Rieju chassis 35 FRONT BRAKE CALIPER Unscrew the join through the screw A F 65 Following unscrew the 2 bolts B F 65 that fix the CALIPER to the front fork ATTENTION A For the later assembly it is advisable to replace the copper gaskets and drain the circuit 36 REAR BRAKE CALIPER Unscrew the join through the screw A F 66 Following unscrew the 2 bolts B F 66 that attach the caliper to the calliper bracket ATTENTION A For the later assembly it is advisable to replace The copper gaskets and drain the circuit
23. tract it pull the lead 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 11 REAR MUDGUARD Remove the seat the pillion seat the rear turn signals and the taillight Unscrew the 2 bolts A F 20 holding the 2 nuts B F 21 of the lower part Rieju chassis Chassis 12 AIR FILTER Remove the seat and the right lateral cover Unscrew the 3 bolts A F 22 of the filter cover and remove the filter a 13 REGULATOR Remove the seat and the right lateral cover Disconnect the regulator from the wiring A F 24 After unscrew the bolt B F 24 to remove it SMX version A ATTENTION Connect the earth cable again during the assembly Rieju chassis Chassis 14 INTERMITTENCE STATION Remove the seat and the left lateral cover Disconnect the intermittence station from the main wiring Following extract it from the rubber 15 FILTER BOX Remove the seat and the rear lateral covers Unscrew the 4 bolts A F 27 at the top After cut the clamp B F 28 that hold the nozzle of the carburettor To extract the filter box pull it backwards Rieju chassi ieju chassis Chassis 16 SHOCK ABSORBER Remove the seat the front lateral covers the rear cowlings and the filter box Unscrew the 2 bolts A F 29 that hold the shock absorber onto the chassis
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