TANGO 2

250
50
Chassis workshop manual
 ENGLIS
Contents

INTRODUCTION

UPDATES FOR THE MANUALS 10

SYMBOLS USED IN THE MANUAL 11
ABBREVIATIONS USED IN THE MANUAL 12
GENERAL WORK RULES 13
RECOMMENDATIONS 14

LEARNING ABOUT THE MOTORCYCLE

MAINTENANCE OPERATIONS 18
TECHNICAL CHARACTERISTICS AND SPECIFICATIONS 18
TIGHTENING TORQUES 21
UNPACKING 22
“AESTHETIC APPEARANCE” CHECK 22
IDENTIFICATION DETAILS 22
IDENTIFYING THE MAIN ELEMENTS 23
CONTROLS AND INSTRUMENTS 24
KEYS 24
STEERING LOCK 24
PROP STAND 25
INSTRUMENT PANEL 25
TYRES 26
CHECKING PRESSURE 26
FUEL TANK 26
TRANSMISSION OIL 27
BRAKE FLUID 28
ADJUSTING THE MINIMUM IDLING RATE 28
ADJUSTING THE TRANSMISSION CHAIN TENSION 29

5
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Contents

REMOVAL

1. SEAT 32
2. SIDE COVERS 32
3. FRONT SIDE COVERS 32
4. REAR COWLING 33
5. SILENCER 33
6. EXHAUST 30
7. “AIS” SYSTEM (secondary air valve) 34
8. BATTERY 34
9. REAR TURN INDICATORS 35
10. REAR LIGHT 36
11. AIR FILTER 37
12. REGULATOR 38
13. TURN INDICATORS CONTROL UNIT 38
14. CENTRAL CDI UNIT 38
15. STARTER RELAY 39
16. GEAR LEVER 39
17. FILTER CANISTER 40
18. SHOCK ABSORBER 41
19. FUEL TANK 42
20. CARBURETTOR 43
21. PROP-STAND 43
22. FRONT MUDGUARD 43
23. ENGINE 44
24. FRONT TURN INDICATORS 45
25. FRONT HEADLIGHT 45
26. INSTRUMENT PANEL 46
27. FRONT BRAKE CYLINDER 46
28. CLUTCH LEVER 47
29. HANDLEBARS 47
30. FRONT BRAKE CALLIPER 47
31. REAR BRAKE CALLIPER 48
32. ODOMETER SENSOR 48
33. FRONT WHEEL 49
34. FRONT BRAKE DISK 49
6
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Contents

REMOVAL

35. STEERING 49
36. FRONT FOOTRESTS 50
37. REAR FOOTRESTS 50
38. REAR BRAKE PEDAL 50
39. CHAIN PROTECTOR 51
40. TRANSMISSION CHAIN 51
41. REAR BRAKE CYLINDER 52
42. KICK-START LEVER 52
43. SWINGING ARM 52

ELECTRICAL SYSTEM

1. PRECAUTIONS 54
2. GENERAL WIRING 54
3. BATTERY 55
4. LIGHTING SYSTEM 56
5. SENSORS 59
6. WIRING DIAGRAM 60

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Introduction

9
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Introduction

This workshop manual contains the main electromechanical checks, as well as the general essential
checks and the fitting of components that are supplied unattached, in order to make delivery of the
motorcycle newly arrived from the factory.

It is very important that the indications given in the manual are adhered to strictly. Work carried
out is a superficial way, or worse still, not carried out at all, may lead to personal injury to the user,
damage to the machine, etc., or simply be the source of disagreeable complaints.

N.B.: Rieju, S.A. reserves the right to make modifications at any time without any prior no-
tification.
For any enquiry of for further information, please call the Rieju, S.A. Customer Service.

UPDATES FOR THE MANUALS

Any update will be sent within a reasonable period of time. Each new CD-Rom updates the informa-
tion in the previous one.
The list of contents will be updated if the modifications and/or variations in the pages do not ensure
the consulting of the manual.

IMPORTANT! The series of workshop manuals must be considered as an actual work instrument,
and the manuals can only maintain their “value” over time if they are kept constantly up to date.

10
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Introduction

SYMBOLS USED IN THE MANUAL

ATTENTION! Practical advice and information that refers to the safety of the
motorcyclist (user of the machine) and the features that maintain the condition
and integrity of the machine itself.

ATTENTION! Descriptions that relate to work that is dangerous for the te-
chnical maintenance staff, repair staff, other workshop staff or for those from
outside, for the environment, for the machine and for the equipment.

DANGER OF FIRE
Operations that could cause a fire.

DANGER OF EXPLOSION
Operations that could lead to an explosion.

TOXIC
Indicates the danger of poisoning or inflammation of the primary respiratory
ICC
OXXI
TTO
tracts.

MEMBER OF TECHNICAL STAFF RESPONSIBLE FOR THE

MECHANICAL MAINTENANCE
Operations that assume competence in the field of mechanics/motorcycles.

MEMBER OF TECHNICAL STAFF RESPONSIBLE FOR

ELECTRICAL MAINTENANCE
Operations that assume competence in the field of electricity/electronics.

NO!
Operations that must be avoided.

WORKSHOP MANUAL
Information to be gleaned from this documentation.

SPARE PARTS CATALOGUE

Information to be gleaned from this documentation.

11
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Introduction

ABBREVIATIONS USED IN THE MANUAL

F Figure
T Tq Tightening torque
P Page
Ap Part
S Section
Diag Diagram
T Table
B Bolt

N.B.:
The illustrations frequently show securing or adjustment bolts or screws, indicated
by the letter B. The number following this letter indicates the quantity of identical
bolts (B) or screws to be found on the unit or component being described and its
corresponding illustration. A letter without a number indicates that the quantity
is 1. In the case of different bolts or screws shown in the same figure, the B will be
followed by the number and by a lower-case letter (e.g.: (B4a)).
The refitting of units and components is normally done in this opposite way to dis-
mantling operations (except for a specific description).

12
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Introduction

GENERAL WORK RULES

• The tips, recommendations and warnings that follow are aimed at ensuring that work
is carried out in a rational way and with maximum operational safety, thereby eliminating
significantly the chances of accidents, injury and damages of any nature and downtimes.
They should therefore be scrupulously observed.

TIPS:
• Always use equipment of an optimum quality.

• Use specially designed equipment, in accordance with European guidelines, to raise the
machine.

• While carrying out work, keep tools within reach, as far as possible according to a
predetermined sequence, and in any event never on the machine or in areas that are
hidden or difficult to access.

• Keep the work area clean and tidy.

• When tightening nuts and bolts, begin either with those with the larger diameter or the
inner ones, proceeding to tighten them in successive steps in a criss-cross pattern.

• The correct method is using a set gap spanner, with a pulling rather than a pushing
action.

• Adjustable spanners (F. 1) should only be used in an emergency, e.g. when the correct
size of set spanner is not available. When force is applied to these, the mobile jaws tend
to open, with the risk of possible damage to the bolt head or nut, as well as obtaining an
unreliable tightening torque. In any event, they must be used as illustrated in Figure 1.

• Except in special service cases, a work sheet should be prepared for the customer, setting
out all the work carried out and notes about any possible future checks.

F-1

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Introduction

RECOMMENDATIONS
• Before beginning any work on the motorcycle, wait for each and every one of the
machine’s components to cool down completely.

• If the operations envisage the use of two mechanics, they need to agree in advance on the
tasks to be performed and synergies.

• Always check that a component has been fitted correctly before proceeding to fit
another.

• Lubricate the (envisaged) parts before refitting them.

• Gaskets, sealing rings, rubber rings and keys must be renewed each time they are
removed.

• The par values indicated in the manuals refer to the “final tightness”, and need to be
reached progressively, step-by-step.

• Loosening and tightening operations on aluminium alloy parts (crankcase) must be

performed when the engine is cold.

• Always use screwdrivers of the correct size for the screws on which they are to be used.

• Never work in uncomfortable conditions or those of precarious stability of the

motorcycle.

• Never re-use a gasket or rubber ring.

• Never tighten or loosen nuts and bolts with pliers, since, in addition to not
exercising enough locking force, this can damage the bolt head or the nut.

• Never strike the spanner with a hammer (or other tool) to loosen or tighten
nuts and bolts (F-2).

• Never increase the leverage by inserting a pipe over the spanner (F-3).

F-2 F-3

14
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Introduction

Never use naked flames under any circumstances.

Never leave open and unsuitable containers containing petrol where others are
passing, close to heat sources, etc.

Never use petrol as a cleaner to clean down the machine or to wash the workshop floor.
Clean the various components with detergent with a low flammability rating.

Never suck or blow into the petrol supply pipe.

Never carry our soldering or welding in the presence of petrol. Remove the fuel tank
even if it is completely empty, and disconnect the negative cable (-) from the battery.

Never leave the motorcycle with the engine running in closed or poorly aired
spaces.

Before carrying out any work, , make sure the motorcycle is perfectly stable.

F-4

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Familiarising yourself with the
motorcycle

17
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Familiarising yourself with the motorcycle

1st SERVICE 2nd SERVICE SER . EVERY

MAINTENANCE OPERATIONS 1.000 KMS. 3.000 KMS. 5.000 KMS.

Check the braking system · · ·

Check the transmission oil level Change
· Change
Check chain tension and wear · · ·
Check suspensions · ·
Check, adjust and grease levers and cables · · ·
Check wheel centring and spoke tensions · ·
Clean and grease the air filter · · ·
Check and adjust the carburettor · ·
Check and adjust the spark plug or renew · · ·
Check the tightness of the nuts and bolts
on the chassis and on plastic units · ·
Check the electrical system · ·
Check wear on piston rings ·
Check the exhaust system ·
Check condition of the battery and its terminals · · ·

TECHNICAL SPECIFICATIONS AND CHARACTERISTICS

Dimensions

Total length 1925 mm.

Total width 800 mm.
Total height 1110 mm.
Seat height 820 mm.
Distance between wheel shafts 1320 mm.
Minimum distance to the ground 250 mm.

Weight

Empty 109 kg.

In running condition 114 kg.

Engine

Type 4 stroke
Number of gears 5 gears
Cylinder and arrangement Single cylinder, forward sloping
Cylinder capacity 249.9 cc
Diameter x stroke 65.5 x 74 mm
Compression ratio 9:1
Starting system Kick-start and electric start
Lubrication system Wet crankcase

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Familiarising yourself with the motorcycle

Transmission oil

Type CASTROL SAE 20W-50 API, “SH” or higher

Quantity 1 litre

Air filter

Type Wet-type foam rubber cartridge

Fuel

Type Lead-free petrol

Fuel tank capacity 7,5 L.

Carburettor

Type DellOrto VHST-28 ECS

Spark plug

Type D8EA / NGK DENSO

Distance between electrodes 0,6 - 0,7 mm.

Clutch

Type Multi-disk in oil bath

Secondary transmission

Engine output sprocket Z = 17

Rear wheel sprocket Z = 44
Transmission ratio 1: 2,58
Chain 428 RN8 x 124 links

GEAR CHANGE
Speed Primary shaft Secondary shaft Gear ratio
1ª Z = 13 Z = 36 1: 2,77
2ª Z = 17 Z = 32 1: 1,88
3ª Z = 20 Z = 28 1: 1,40
4ª Z = 23 Z = 26 1: 1,13
5ª Z = 25 Z = 24 1: 0,96

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Familiarising yourself with the motorcycle

Suspension

Front PAIOLI telescopic forks

0.37 mm bars
340 cc CASTROL SAE I5W per bar

Rear Hydraulic shock absorber

Brake disks

Front 260 mm. Ø

Rear 200 mm. Ø

Mixed/road tyres

Front 100/80-17” 55P

Rear 130/70-17” 63P

Enduro tyres

Front 90/100-19”
Rear 120/90-16

Electrical equipment

Ignition system C.D.I.

Generator AC 120 w magneto generator
Battery 12 V - 5,5 Ah
Fuse 15 Amp

Voltage and wattage of bulbs

Headlight 12V 55/60W H4

Rear light 12V 21/10W
Instrument panel 12V 1,2W
Turn indicators 12V 10W
Odometer lighting Leds

20
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Familiarising yourself with the motorcycle

TABLE OF TIGHTENING TORQUES

Element N*m Kg*m Notes
Front wheel bolt 38 - 52 3,8 - 5,2
Front wheel bolt lock 17 - 23 1,7 - 2,3 G

Rear wheel bolt 72 - 98 7,2 - 9,8 G

Front/rear brake calliper 24 - 36 2,4 - 3,6

Silencer 6 - 10 0,6 - 1,0
Exhaust pipe side coupling 6 - 10 0,6 - 1,0
Engine mounting bolt 20 - 26 2,0 - 2,6
Handlebar lever bolt 2-4 0,2 - 0,4
Shock absorber bolts 38 - 52 3,8 - 5,2
Forks bolt 51 - 69 5,1 - 6,9 G

Handlebar securing bolt 18 - 24 1,8 - 2,4

Top steering nut 18 - 24 1,8 - 2,4
Intermediate steering nut 25 - 34 2,5 - 3,4 G

Swinging arm bolt 60 - 75 9,0 - 7,5

G Grease

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Familiarising yourself with the motorcycle

UNPACKING

• Unpack the motorcycle following the directions present in the packaging itself, which must
then be disposed of in accordance with existing regulations.

“AESTHETIC APPEARANCE” CHECK

• Check visually that all components made of plastic material are fitted correctly and that
the motorcycle does not have any visible scratches, marks, etc.

DETAILS FOR IDENTIFICATION

Machine Identification Number

• The motorcycle’s identification number (A/F-1) is stamped onto the steering cylinder.

Engine identification number

• The details for identifying the engine (B/F-2) can be seen on the right-hand crankcase.

A B

F-1 F-2

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Familiarising yourself with the motorcycle

IDENTIFICATION OF MAIN ELEMENTS

(left-hand side)
2 3 4 5 1. Headlight.
2. Right-hand controls.
3. Left-hand controls.
4. Seat.
5. Exhaust pipe.
1 6. Rear grab bar.
7. Prop stand.
8. Gear change pedal.
9. Fuel tank.
6

9 8 7 F-3

IDENTIFICATION OF MAIN ELEMENTS

(right-hand side)
10 10. Fuel tank cap.
11. Forks.
12. Rear brake pedal.
11 13. Kick-start lever.
14. Pillion passenger foot-rests.
15 15. Number plate light and
number plate holder.

14 13 12 F-4

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Familiarising yourself with the motorcycle

CONTROLS AND INSTRUMENTS

1 2 3 4 5 6

13 12 11 10 9 8 7

F-5

1. Rear-view mirror. 6. Front brake lever. 11. Turn indicators switch.

2. Clutch lever. 7. Throttle twist grip. 12. Horn button.
3. Instrument panel. 8. Starter button. 13. Left-hand handlebar grip.
4. Main switch. 9. Fuel tank cap.
5. Front brake cylinder. 10. Light switch
(dipped beam/main beam).

KEYS

• The motorcycle is supplied with two keys, with a numeric code, that allow:
- The ignition to be switched on.
- The lights to be switched on.
- The steering to be locked.

STEERING LOCK

• Locking: With the handlebars turned fully to the left, push the key fully in and turn it to
the left.
• Unlocking: Turn the ignition key to the right.

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Familiarising yourself with the motorcycle

PROP STAND

• Check that the prop stand is well secured

and moves properly. The retention system,
consisting of traction springs, should also be
checked frequently.

A F-6

INSTRUMENT PANEL

1- Turn indicators indicator light

This indicator light flashes when the turn indicator switch is moved to the left or to the
right.

2- Oil level indicator light

This indicator light comes on when the oil level is low.

3- Coolant temperature indicator light

This indicator light comes on when the coolant temperature is too high. When the indi-
cator light comes on, stop the engine immediately.

4- Mode button.
See programming section.

5- “N” neutral indicator light.

This indicator light comes on when the transmission is in the neutral position.

6- Main beam indicator light.

This indicator light comes on when the headlight is on main beam.

4
6

25
5 F-7
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Familiarising yourself with the motorcycle

TYRES

Dimensions

position dimensions

FRONT 90/100 - 19 55P

REAR 120/90 - 16 63P

CHECKING THE PRESSURE

Tyre pressures should be checked and adjusted with the tyres at ambient temperature.

position bar

FRONT 1,7 kg / cm2

REAR REAR 2,0 kg / cm2

FRONT

F-8

FUEL TANK
Unscrew the cap. Top up the tank, paying attention not to exceed the limit. If spilt petrol is
observed on the motorcycle, clean it off immediately. Use normal lead-free petrol.

Fuel tank capacity: Total: 7 litres

F-9
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Familiarising yourself with the motorcycle

TRANSMISSION OIL

Changing the oil

1. Stand the motorcycle on a flat surface.

2. Warm up the engine for several minutes.

3. Stop the engine. Place a container under the engine to hold the oil.

4. Extract the drain bolt (B/F-11) and the filler cap (C/F-12) to allow the oil to flow out.

5. When it has completely drained out, replace the drain bolt (B/F-11) and tighten it.

6. Fill the engine with fresh oil. Check the engine oil level using the inspection window (A/F-10).

7. Fit the filler cap (C/F-12) and tighten it.

The recommended engine oil is CASTROL SAE 20W-50 API, “SH” or higher.

7. Start up the engine and warm up for a few minutes. While the engine is warming up, check
that there are no oil leaks. If there are, stop the engine immediately and discover what the
cause is.

A
F-10

F-11 F-12
27
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Familiarising yourself with the motorcycle

A B
BRAKE FLUID

Check
MIN
When checking the fluid level, turn the han-
dlebars to ensure that the top of the master
cylinder is level.

Check that the brake fluid level is above the

minimum level mark on the rear brake fluid
reservoir, and check that there is fluid for the
front brake by looking through the inspection F-13
hole in the cylinder.

Changing the fluid C

For the front brake, remove the cover (A/F-

13) after removing the bolts (B/F-13). For the
rear brake, remove the cap (C/F-14).
MAX
For the rear brake, remove the cap (C/F-14).
The quality of the fluid used must comply with MIN
the standards specified; since otherwise the
rubber seals may deteriorate, causing leaks
and reducing the effectiveness of the brakes.

Recommended brake fluid: DOT 4 F-14

ATTENTION: Brake fluid is corrosive.

ADJUSTING THE IDLING RATE

Start the engine and warm it up for a few minu-
tes at 1,000 to 2,000 rpm, increasing it gradua-
lly up to a rate of 4,000 to 5,000 rpm. When
the engine responds quickly to the throttle,
this means that the engine has warmed up. A

Adjust the engine idling speed by turning the

fuel adjustment screw (A/F-15). Screwing in in-
crease the rate, and unscrewing decreases it.

Check the ideal rate for the engine using an

electronic tachometer connected to the spark
plug cable.
F-15
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Familiarising yourself with the motorcycle

ADJUSTING THE TRANSMISSION CHAIN TENSION

The chain is adjusted by loosening the rear wheel shaft and screwing in or unscrewing the
nuts and bolts adjacent to the shaft (A/ F-16), ensuring that there is the same distance on
both sides of the shaft at all times.

ATTENTION: Poor chain and wheel alignment may cause the chain to come off, as well
as problems of stability on the motorcycle.

To check and adjust the chain, act on the rear wheel shaft, making sure to work at the point
of maximum tension in the chain at all times.

To check the free play, turn the rear wheel several times and check the tension at several
points in order to find the point with the highest tension.

The motorcycle must be standing upright with its two wheels on the ground, and the free
play of the chain should be from 20 to 35mm. (F-17).

Be careful not to over-tighten the chain as this may cause damage to the engine and to the
transmission. Keep the chain tension within the limits specified in the attached diagrams.

20-35 mm
F-16 F-17

The chain should be cleaned and lubricated periodically. The chain is formed of
a large number of parts that work one with the other. Failure to maintain the
chain properly will cause it to wear rapidly, and it is therefore recommended to
lubricate the chain periodically, using special chain lubrication oil.
Prior to lubrication the chain needs to be cleaned with a brush or a cloth to re-
move dirt and mud on the chain, and then apply the lubricant between the side
plates, and on all the central rollers.

29
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Removal

31
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Removal

1. SEAT

Insert the key into the lock (A/F-1) located on the rear right-hand side and turn it to the
right to release the seat.
Then lift the seat at the rear and pulling it backwards to withdraw it from the front anchor
point (B/F-2).

A B
F-1 F-2

2. SIDE COVERS

* Remove the seat.

Remove the screw from the rear (A-/F-3).

F-3

3. FRONT SIDE COVERS

Unscrew the bolt (A-/F-4) and the bolt (B-/F-5) situated at the bottom rear.

A B

32 F-4 F-5
 ENGLIS
Removal

4. REAR COWLING

* Remove the seat.

Unscrew the 2 bolts (A/F-6). A

The remove the 2 spacers (B/F-6) and withdraw
from the front.

F-6

5. SILENCER
Loosen the clamp (A/F-7) on the connection between the exhaust pipe and the silencer.
Then unscrew the 2 bolts (B/F-8) securing the silencer to the chassis.
To extract it, pull the silencer backwards.

ATTENTION: Before removing the silencer, make sure it has cooled down.

F-7 F-8

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Removal

6. EXHAUST PIPE

Loosen the clamp (A/F-9) on the connection between the exhaust pipe and the silencer.
Remove the 2 nuts (B/F-10) securing the exhaust pipe to the engine at the front.

ATTENTION: Before removing the exhaust pipe, make sure it has cooled down.

A
F-9 F-10

7. “AIS” SYSTEM (Secondary air valve)

Disconnected the clamps from the pipes (A/F-11).

Then unscrew the 2 securing bolts (B/F-11).
IN
A
OUT

B A
ATTENTION: Pay attention
to the position of the valve, to
ensure it is refitted correctly. If
it is not fitted correctly, it may
F-11 burn out.

8. BATTERY

*Remove the seat.

Disconnect the two cables. B

Positive (A/F-12) red.

Negative (B/F-12) black. A

34
F-12
 ENGLIS
Removal

9. REAR TURN INDICATORS

Unscrew the 2 bolts (A/F-13) from the wheel arch protector and the rear nut (B/F-14).

Disconnect the cables (C/F-15) from the general wiring.

Then loosen the screw (D/F-16) securing the nut on the inside, and pull out the cable to
remove the light.

ATTENTION: Before removing the lights, pay attention to the sequence of the terminals
for later refitting (see wiring diagram).

B
A

F-13 F-14

D
C
F-15 F-16

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Removal

10. REAR LIGHT

* Remove the wheel arch protection cover (See 9. Rear turn indicators).

Disconnect the terminal (A/F-17) from the wiring.

Then loosen the two screws (B/F-18) securing the rear light cover.

To extract it, pull the cable (C/F-19) to remove the light.

ATTENTION: Before removing the lights, pay attention to the sequence of the termi-
nals for later refitting (see wiring diagram).

B
A
F-17 F-18

F-19

36
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Removal

11. AIR FILTER

*Remove the seat and the right-hand side cover.

Unscrew the 3 screws (A/F-20) from the filter cover.

Then remove the filter (B/F-21).

ATTENTION: When refitting, situate the fin (C/F-22) on the filter forwards as indicated
in the image.

ATTENTION: This type of filter is always kept wet with oil.

F-20 F-21

F-22

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Removal

12. REGULATOR

*Remove the seat and the left-hand side cover.

Disconnect the regulator from the wiring (A/F-23).

Then unscrew the 2 nuts (B/F-22) to withdraw it. B

A F-23

13.TURN INDICATORS CONTROL UNIT

*Remove the seat and the left-hand side cover.

Disconnect the turn indicators control unit

(A/F-24) from the general wiring.

Then extract it from the rubber (B/F-24).

A
F-24

14. CENTRAL CDI UNIT

*Remove the seat.

Unscrew the 2 bolts (A/F-25) from the bracket.

Disconnect the central CDI unit (B/F-25) from A

the general wiring.

A
F-25
38
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Removal

15. STARTER RELAY

* Remove the seat and the left-hand side cover.

ATTENTION: Cover the relay terminals with a protector to prevent them from short-
circuiting with the chassis.

Disconnect the starter relay (A/F-26).

Remove the starter relay from the bracket (B/F-27).
A spare fuse (C/F-28) is housed at the back of the securing rubber.

A B

A A

F-26 F-27

F-28

16. GEAR LEVER A

Unscrew the securing bolt (A/F-29).

Then pull off the lever, taking care not to dama-

ge the shaft splines.

F-29
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Removal

17. FILTER CANISTER

* Remove the seat, the fuel tank and the silencer.

To make the task easier, unscrew the 2 bolts (A/F-30) from the rear of the chassis and
loosen the 2 front ones (B/F-30).

Loosen the nozzle (C/F-31) from the carburettor and the breather pipe.

Then unscrew the 4 bolts (D/F-32) from the top of the canister.

To extract it, lift the rear chassis (F-33) and remove it.

C
A
F-30 F-31

D
F-32 F-33

40
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Removal

18. SHOCK ABSORBER

*Remove the seat and the filter canister.

To make the task easier, unscrew the 2 bolts (A/F-34) from the rear of the chassis and loo-
sen the 2 front ones (B/F-34).

Unscrew the 2 bolts (C/F-35) securing the shock absorber to the chassis and withdraw
backwards.

ATTENTION: Before removal, secure the chassis at the bottom to prevent the swinging
arm and the wheel from falling.

ATTENTION: Pay attention to the position of the shock absorber, to ensure it is refitted
correctly.

C
B

A
F-34 C F-35

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Removal

19. FUEL TANK

*Remove the seat.

ATTENTION: Before removal, shut the fuel tap on the tank.

Remove the fuel tap clamp (A/F-36).

Unscrew the 3 screws (B/F-37) securing the tank to the chassis.

Then remove the cap and separate the protector from the tank (C/F-38).

Place a container under the tank and drain out the petrol by removing the clamp (D/F-39).

F-36 F-37

F-38 F-39

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Removal

20. CARBURETTOR

*Remove the seat and the fuel tank.

B

Loosen the 2 clamps (A/F-40) securing the A

carburettor to the filter canister and to the
engine.

Disconnect the throttle cables (B/F-40). Dis-

connect the choke cable (C/F-40).
C
Then disconnect the suction hose and the
remaining pipes. B F-40

ATTENTION: Pay attention to the position of the pipes, to ensure they are refitted
correctly.

21. PROP STAND

ATTENTION: Secure the motorcycle befo-

re carrying out this operation.
A
ATTENTION: Carry out this operation
with the prop stand folded up.

Remove the tensioning spring (A/F-41).

Then unscrew the bolt (B/F-41).

B
F-41

22. FRONT MUDGUARDS (ENDURO as an example)

Unscrew the 4 bolts (A/F-42), two on each

side, securing the mudguard to the forks.
A
Withdraw it forwards.

F-42
43
ENGLISH

Removal

23. ENGINE

* Remove the front side covers, the carburettor and the exhaust pipe.
To make the task easier, remove the rear brake pedal.

Disconnect the SPARK PLUG, the CLUTCH CABLE, the ENGINE AIR INTAKE,
the CARBURETTOR and the TRANSMISSION CHAIN.

Gain access from the top to disconnect the 2 terminals from the engine (C/F-44).

Unscrew the 2 bolts (A/F-43) from the front engine mounting.

Then unscrew the 4 bolts (B/F-43) securing the engine.

F-43

44

F-44
 ENGLIS
Removal

24. FRONT TURN INDICATORS

Disconnect the light from the general wiring (A/F-45).

Then loosen the screw (B/F-46) securing the nut on the inside, and pull out the cable to
remove the light.

ATTENTION: Pay attention to the position of the cables, to ensure they are refitted
correctly.

F-45 F-46

25. FRONT HEADLIGHT (ENDURO as an example)

* To make the task easier, unscrew the 3 bolts on the fuel tank and move it clear to access
the headlight connection.

Disconnect the headlight terminal (A/F-47) from the wiring.

Then unscrew the 2 screws (B/F-48) securing the headlight.

F-47 F-48

45
ENGLISH

Removal

26. INSTRUMENT PANEL

Remove the headlight trim (A/F-49) to access the odometer connections.

Disconnect the odometer (B/F-50).

Then unscrew the 2 top screws (C/F-50) securing the screen to the bracket.

F-49 C F-50

27. FRONT BRAKE CYLINDER

Disconnect the brake light micro-switch terminals (A/F-51).

Unscrew the connector (B/F-52) securing the pipe to the cylinder.

Then unscrew the 2 screws (C/F-52) and remove the front brake cylinder.

ATTENTION:
The copper gaskets should be renewed and the circuit bled when refitting the brake cylin-
der.

ATTENTION: Brake fluid is corrosive.

F-51 F-52
46
 ENGLIS
Removal

28. CLUTCH LEVER

Disconnect the clutch cable (A/F-53) and the choke cable (B/F-53).

Then unscrew the 2 screws (C/F-54) and remove the lever.

F-53 F-54

29. HANDLEBARS

*Remove the controls on each end.

Unscrew the 4 bolts (A/F-55) and remove the

A
handlebars.
A

F-55

30. FRONT BRAKE CALLIPER

Unscrew the connector using the bolt (A/F-56).

Then unscrew the 2 bolts (B/F-56) securing

the calliper to the front forks. A

ATTENTION: B
The copper gaskets should be renewed and
the circuit bled when refitting the calliper.

F-56
ATTENTION: Brake fluid is corrosive.

47
ENGLISH

Removal

31. REAR BRAKE CALLIPER

Unscrew the connector using the bolt (A/F-57).

A
Then unscrew the 2 bolts (B/F-57) securing
the calliper to the calliper bracket.

ATTENTION:
The copper gaskets should be renewed and
the circuit bled when refitting the calliper.
B
F-57
ATTENTION: Brake fluid is corrosive.

32. ODOMETER SENSOR

Remove the headlight trim (A/F-58).

Disconnect the sensor (B/F-59) from the wiring.
Remove the clips holding the cable along the length of the chassis.
Remove the bolt securing the bracket (C/F-60).

A
B

F-58 F-59

F-60
48
 ENGLIS
Removal

33. FRONT WHEEL

Unscrew the nut (A/F-61).

Loosen the wheel shaft securing bolt (B/F-62) located on the forks.
Remove the wheel shaft (C/F-62).

C
A
F-61 F-62

34. FRONT BRAKE DISK

* Remove the front wheel.

Unscrew the bolts (A/F-63) securing the disk.

F-63

35. STEERING

Unscrew the 4 handlebar screws (A/F-64).

Loosen the 2 side bolts (B/F-64) to aid its ex- A

traction.

Extract the top nut (C/F-64) and remove the

top plate. C

To remove the wheel shaft, unscrew the nut

(D/F-64).
B D

F-64
49
ENGLISH

Removal

36. FRONT FOOTRESTS

Unscrew the screw (A/F-65) securing the nut

A
(B/F-65).

ATTENTION:
Make a note of the position of the spring so
that it can be refitted correctly.

F-65

37. REAR FOOTRESTS

Unscrew the bolt (A/F-66) securing the nut

(B/F-66).
B

F-66

38. REAR BRAKE PEDAL

Remove the cotter pin (A/F-67).

Then remove the bolt (B/F-67), the pedal and
the internal spring (C/F-67).

F-67
50
 ENGLIS
Removal

39. CHAIN PROTECTOR

Unscrew the 2 screws (A/F-68) and remove

the protector.

A
A
F-68

40.TRANSMISSION CHAIN

Remove the 2 bolts (A/F-69) securing the protector and remove it. Extract the clip (B/F-
70) securing the connector link and remove the chain.

ATTENTION: When refitting, consult the Adjusting the transmission chain tension
section.

B
A

F-69 F-70

ATTENTION: Make a note of the position of the chain, to ensure it is refitted correctly.

51
ENGLISH

Removal

41. REAR BRAKE CYLINDER

Unscrew the 2 bolts (A/F-71).

To remove the cylinder it is necessary to dis- B

connect the STOP switch (B/F-71) and unscrew
it.
A
Remove the clamp (C/F-71) from the brake fluid
supply tube and drain into a container. C

ATTENTION: Brake fluid is corrosive.

F-71

42. KICK-START LEVER

Unscrew the nut (A/F-72) and extract the

lever by pulling it off.

ATTENTION: Refitting the lever in a diffe-

rent position to the original may reduce the
travel during kick-starting.

F-72

43. SWINGING ARM

* Remove the chain, the rear brake calliper, the rear wheel and shock absorber.

Unscrew nut (A/F-73) and withdraw the shaft (B/F-74) from the other end.

F-73 F-74
52
 ENG
Electrical system

53
 Electrical system

1. PRECAUTIONS

There are a number of important precautions to be taken before beginning to inspect or

repair the electrical system.

• Special attention must be paid to the polarity of the battery.

• Always check the condition of the battery on beginning any repair.

• Charge the battery away from the machine to avoid possible spilling of acid or faults in the
charger clips contacts that could damage an electronic component.

• Do not handle the battery or other connections with the ignition on or the engine running,
as this could damage electronic components.

• Do not fit bulbs in the lights or instruments that are different to those specified.

• Do not carry out welding with an electric welder or any operations that produce sparks
without disconnecting the coil/CDI, as this could damage this equipment.

• Before taking electrical resistance measurements, make sure that the part is not hot.

• All the connections must be clean and well-tightened.

2. GENERAL WIRING
Checks to be carried out on the wiring:

• Check visually that the wiring has not deteriorated or that the connectors and terminals
are not loose or dirty.

Any elements found to be in a poor condition must be renewed.

• If not defects are detected visually, cables of the same colour and diameter should be
checked for a circuit using a meter.

To carry out this check, the wiring needs to be disconnected.

• Cables of the same colour and diameter should have a circuit between them.

METER SCALE Ω X 1

54
 ENGLIS
Electrical system

3. BATTERY
CHECKING THE CONDITION OF THE BATTERY
• The battery should be removed from the machine to carry out checks.

• When removing it, first disconnect the negative terminal to avoid any possible short
circuits.

• The condition of hermetically-sealed batteries can be checked by measuring voltage

across the terminals with a digital meter that can measure tenths of volts.

• Should the voltage be below that specified, the battery needs to be recharged.

The standard voltage across the terminals should be 12.5V or higher.

PROCEDURE FOR RECHARGING

Recharging hermetically-sealed batteries requires a charger with a specially stabilised output

for this type of battery.
These batteries are sealed. Do not add liquid nor open the plugs. This will modify the
characteristics and damage the battery.

Do not charge over 1/10th of its capacity.

SYSTEM FOR DETERMINING THE LENGTH OF CHARGE

In order to determine the length of time the battery should be on charge, the voltage across
the terminals should be measured using a meter.

Then noting the voltage axis on the graph, draw a vertical line until it intersects the slope of
the charge, and a horizontal one to the time axis in hours.

Example:
Observing the graph.

If we measure 12V across the terminals, we draw a line up from the 12V to intersect the
slope, and a horizontal one up to approx. 8 hours.
The charging time for the battery would be approx. 8 hours.
Charging time

Graph of the charging time in terms of the

Voltage at the battery terminals voltage at the terminals.
55
 Lighting system

4. LIGHTING SYSTEM

Adjusting the height of the front headlight beam

horizontal

main beam
Height at the centre
of the headlight

5 metres

With the rider seated on the machines, the headlight beam should be adjusted in such a
way that the main beam is situated below the headlight horizontal.

In case of having to change a bulb, avoid touching the inside of the headlight with the
hands. In addition, the new bulb should be handled with a clean cloth.

Checking the switches:

Checking the ignition switch

IGNITION SWITCH

ON
OFF
LOCK
5
GR/BCK
YW
OR
GR

Use a meter to check that there is a circuit between the ignition switch connector cables.

ON position – circuit between cables Colour: GR and OR

GR/BCK&YW

56
 ENGLIS
Lighting system

Checking right-hand light switch and start button.

STAR
BUTTON
ON
OFF

W/BL
W/BL
Check that there is a circuit between the connector cables.

Start button ON button position – circuit between the cables

Colour: W/BL and W/BL

Checking the right controls: Light switch, turn indicator switch and horn button.

TURN INDICATOR
SWITCH
HORN LIGHT
BUTTON R/HAND SWITCH
OFF OFF HI
ON L/HAND LO
Light GR
Dark GR

BL/RED
W/BR
RED
BLK

YW
BR

Check that there is a circuit between the connector cables.

Horn button
ON position Circuit between the cables Colour: RED/BLK

Turn indicators switch

R/HAND position. Circuit between cables Colour: Dark GR and W/BR

L/HAND position. Circuit between the cables Colour: W/BR and BR

Light switch
HI position. Circuit between the cables Colour: YW and BL/RED

LO position. Circuit between the cables Colour: BL/RED and Light GR

57
 Lighting system

Checking the contact relay

With relay terminals 85 and 86 connected to a battery, check the circuit between terminals
30 and 87.

The meter should register 0 Ω

On disconnecting the battery, it should register infinity.

The meter should register ∞ (infinity)

Checking the turn indicator relay

BCK
VI
BR
W L

12V 10W bulbs

12V battery

Connect the turn indicator relay according to the diagram to check if it flashes. The bulbs
can be replaced by 12V and 21W ones.

58
 ENGLIS
Checking the instruments

5. SENSORS

Neutral sensor

To check this sensor, the circuit should be checked between the terminal and earth.
With the gearbox in neutral, it should register 0Ω
On selecting a gear the meter should register ∞ (Infinity).

Checking the diode

VI VI BLK

6. Ambient temperature sensor.

7. Carburettor thermal resistance.

Checking the ambient temperature sensor

Check the resistance with the meter between the ends of the sensor - under
11° C +/- 3 the resistance value is 0Ω.
When the temperature rises, it should switch off at 16° C, and the Ω value should
be infinity.

Checking the thermal resistance

To check whether the thermal resistance works properly, it should be connected to

a 12V battery and should warm up within a few seconds.

59
 Electrical system

6. WIRING DIAGRAM

60
 RIEJU, S.A. c/.Borrassà, 41 E-17600 FIGUERES, GIRONA (SPAIN)
Telf. +34 / 972500850 Fax +34 / 972506950 www.riejumoto.com / e-mail [email protected]