RIEJU MRX-SMX 50 Chassis Workshop Manual
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RIEJU MRX-SMX 50 Chassis Workshop Manual

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MRX-SMX 50
MRX-SMX 50
C h a s s i s w o r k s h o p m a n u a l

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Summary of Contents for RIEJU MRX-SMX 50

  • Page 1 MRX-SMX 50 MRX-SMX 50 C h a s s i s w o r k s h o p m a n u a l...

  • Page 2: Table Of Contents

    Index Chassis INTRODUCTION MANUAL UPDATES SYMBOLOGY USED IN THE MANUAL ABBREVIATIONS USED IN THE MANUAL GENERAL WORK RULES RECOMMENDATIONS 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...
  • Page 3 Index Chassis DISASSEMBLY 1. REAR VIEW MIRRORS 2. FRONT HEADLIGHT HOLDER 3. FRONT SIDE COVERS 4. SEAT 5. NUMBER PLATE HOLDER 6. REAR COVER 7. FRONT MUDGUARD 8. FUEL TANK 9. FUEL TANK PROTECTOR 10. HANDLEBARS 11. STEERING 12. CLUTCH LEVER 13.
  • Page 4 Index Chassis 35. REAR BRAKE CYLINDER 36. REAR BRAKE CALLIPER 37. ENGINE 38. REAR WHEEL 39. CHAIN PROTECTOR 40. DRIVE CHAIN 41. SHOCK ABSORBER 42. SWING ARM 43. FRONT WHEEL 44. FRONT BRAKE CALLIPER 45. FRONT BRAKE DISK 46. SPEED SENSOR 47.
  • Page 5 Introducción Chassis...
  • Page 6 Introduction Introduction...

  • Page 7: Manual Updates

    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.

  • Page 8: Symbology Used In The Manual

    Introducción Chassis SYMBOLOGY USED IN THE 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.

  • Page 9: Abbreviations Used In The Manual

    Introducción Chassis ABBREVIATIONS USED IN THE MANUAL Figure Pr Tr 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.

  • Page 10: General Work Rules

    Introducción 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: •...

  • Page 11: Recommendations

    Introducción 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. •...
  • Page 12 Introducción Chassis Never use open flames for any reason. Never leave open containers or containers not suitable for holding fuel in passageways, close to heat sources, etc Never use petrol to clean the vehicle or the floor of the workshop. Always use low flash point solvents to clean the vehicle components.

  • Page 14: Getting To Know The Motorbike

    Getting to know the motorbike Getting to know the motorbike...
  • Page 16 Rieju chassis Chassis SERVICE SERVICE ER. EVERY AINTENANCE OPERATIONS 1.000 3.000 5.000 · · · Brake system checking · Transmission oil level checking Change Change · · · Chain tension and wear inspection · · Suspension control · · ·...
  • Page 17 Rieju chassis Chassis Transmission oil Type CASTROL MTX SAE 10W 40 Quantity 820 c.c. Air filter Wet type foam rubber cartridge Fuel Type 95 Unleaded petrol 8,4 L. Tank capacity Carburettor Dellorto PHBN 16 HS Spark plug NGK BR 9 ES...
  • Page 18 Rieju chassis Chassis Suspension MRX / SMX MRX / SMX Front Inverted hydraulic fork Ø 35 mm CASTROL OIL FORK 15W 20, 245 cc per bar Rear Hydraulic damper MRX PRO / SMX PRO Suspension PAIOLI Inverted hydraulic fork Front Ø...

  • Page 19: Unpacking

    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.
  • Page 20 Rieju chassis Chassis IDENTIFICATION OF THE MAIN PARTS (Left side) 1. Headlight 2. Oil mixing tank 3. Battery (SMX) 4. Gear pedal IDENTIFICATION OF THE MAIN PARTS (Right side) 5. Radiator 6. Tool box 7. Fuel tank cap 8. Rear brake pedal 9.

  • Page 21: Controls

    Rieju chassis Chassis CONTROLS Controls/Instruments 1. Main switch 2. Clutch lever 3. Turn signal switch 4. Dashboard 5. Start lever 6. Front brake pump 7. Front brake lever 8. Accelerator grip 9. Horn switch 10. Lights switch (Dipped and full-beam headlights) KEYS •...
  • Page 22 Rieju chassis Chassis DASHBOARD Steering warning light This warning light twinkles when the steering switch moves towards the left or the right. Coolant temperature warning light This warning light lits when the temperature of the coolant is too much high. If this happens, stop the engine immediately.

  • Page 23: Tyres

    Rieju chassis Chassis TYRES Dimensions 80/90-21 48 P (enduro front) 110/80-18 58 P (enduro rear) 100/80-17 52 S (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”.

  • Page 24: Coolant

    Rieju chassis Chassis COOLANT Control 1. 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.

  • Page 25: Engine Oil

    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.

  • Page 26: Brake Fluid

    Rieju chassis Chassis BRAKE OIL Control When the oil level is going to be checked, turn the handlebar to verify that the upper part of the main cylinder is levelled out. Check the oil level is above the mark of the- minimum level in the tray of the rear brake.
  • Page 27 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 correct 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.
  • Page 28 Disassembly Disassembly...

  • Page 29: Seat

    Rieju chassis Chassis 1. SEAT Unscrew the nut (A/F -1) located inside the cavity of the rear wheel. After, lift the seat off the back and pull it backwards to remove it from the front catch. 2. REAR LATERAL COVERS * Remove the seat.
  • Page 30 Rieju 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.
  • Page 31 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 (C/F -11).
  • Page 32 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. F-14 F-15 9. REAR TURN SIGNALS Cut the clamp that hold the leads and disconnect them from the main wiring.
  • Page 33 Rieju chassis Chassis 10. TAILLIGHT Cut the clamp that hold the leads and disconnect them from the main wiring. After, loosen the 2 screws (A/F -19) that attach the light to the fender. To extract it, pull the lead to remove the light.
  • Page 34 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. F-22 F-23 13. REGULATOR * Remove the seat and the right lateral cover.
  • Page 35 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. F-26 15. FILTER BOX * Remove the seat and the rear lateral covers.
  • Page 36 Rieju 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. Then, remove it from the back.

  • Page 37: Fuel Tank

    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. F-31 F-32 19. OIL TANK * Remove the seat, the left front lateral cover and disconnect the level sensor wire and the oil filter.
  • Page 38 Rieju chassis 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. F-35 F-36 21.
  • Page 39 Rieju chassis Chassis 22. FUEL TANK * Remove the seat and the front lateral covers. ATTENTION: Before disassembly, close the fuel 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.
  • Page 40 Rieju chassis Chassis 23. TRANSMISSION/OIL MIXING Unscrew the 2 bolts of the cover. Move the tensor backwards and remove the throttle cable. F-42 F-43 24. CARBURETTOR * Remove the seat, the front cowlings and the fuel tank (only move it away).
  • Page 41 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.
  • Page 42 Rieju chassis Chassis 26. RADIATOR * Remove the seat and 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 (C/F-51).
  • Page 43 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 F-54 F-55 29. FRONT MUDGUARDS Unscrew the 4 bolts (A/F -56) located at the lower part of the mudguards.
  • Page 44 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.

  • Page 45: Front Brake Master Cylinder

    Rieju 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.

  • Page 46: Front Brake Caliper

    Rieju chassis 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: For the later assembly it is advisable to replace the copper gaskets and drain the circuit.

  • Page 47: Steering

    Rieju chassis Chassis 38. ODOMETER SENSOR 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). F-68 F-69 39.
  • Page 48 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 F-72 F-73 42. REAR FOOTREST Unscrew the bolt (A/F -74) holding the lower nut.
  • Page 49 Rieju chassis Chassis 44. DRIVE CHAIN GUARD Unscrew the 2 bolts (A/F -76) and remove the guard. F-76 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.
  • Page 50 Rieju chassis Chassis 46. REAR 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. F-79 Remove the clamp (C/F-80) of the brake fluid delivery pipe and empty it in a tray.
  • Page 51 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. F-82...

  • Page 52: Exhaust

    Rieju chassis Chassis 49. PARES DE APRIETE TORQUE TABLE Element Kg*m Notes Front wheel bolt 38 - 52 3,8 - 5,2 Front wheel lock bolt 17 - 23 1,7 - 2,3 72 - 98 7,2 - 9,8 Rear front bolt...

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